Trane CVHH CenTraVac Installation, Operation And Maintenance Manual 128 Pages

Trane CVHH CenTraVac Installation, Operation And Maintenance Manual
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Trane CVHH CenTraVac Installation, Operation And Maintenance Manual | Manualzz

Installation, Operation, and Maintenance

CVHH Water-Cooled CenTraVac ™ Chillers

With Tracer® AdaptiView™ Control

CVHH

X39641257007

Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.

February 2018

Introduction

Read this manual thoroughly before operating or servicing this unit.

Use the following checklist when testing UAT CRs/

MyTickets.

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

NOTICE

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It could also be used to alert against unsafe practices.

Indicates a situation that could result in equipment or property-damage only accidents.

Important Environmental Concerns

Scientific research has shown that certain man-made chemicals can affect the earth’s naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon

(CFCs) and those containing Hydrogen, Chlorine,

Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants-including industry replacements for CFCs and HCFCs such as saturated or unsaturated HFCs and HCFCs.

Important Responsible Refrigerant

Practices

Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified according to local rules. For the USA, the Federal Clean Air Act (Section

608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

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X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

CVHH-SVX001G-EN 3

4

X39003892001A application only.

Factory Warranty Information

Compliance with the following is required to preserve the factory warranty:

Startup MUST be performed by Trane, or an authorized agent of Trane, to VALIDATE this WARRANTY.

Contractor must provide a two-week startup notification to Trane (or an agent of Trane specifically authorized to perform startup).

d R ea blly

When a new chiller is shipped and received from our

Trane manufacturing location and, for any reason, it requires disassembly or partial disassembly, and reassembly— which could include but is not limited to the evaporator, condenser, control panel, compressor/ motor, economizer, purge, factory-mounted starter or any other components originally attached to the fully assembled unit— compliance with the following is required to preserve the factory warranty:

• Trane, or an agent of Trane specifically authorized to perform start-up and warranty of Trane ® products, will perform or have direct on-site technical supervision of the disassembly and reassembly work.

• The installing contractor must notify Trane—or an agent of Trane specifically authorized to perform startup and warranty of Trane ® products—two weeks in advance of the scheduled disassembly work to coordinate the disassembly and reassembly work.

• Start-up must be performed by Trane or an agent of

Trane specifically authorized to perform startup and warranty of Trane ® products.

Trane, or an agent of Trane specifically authorized to perform start-up and warranty of Trane ® products, will provide qualified personnel and standard hand tools to perform the disassembly and reassembly work at a location specified by the contractor. The contractor shall provide the rigging equipment such as chain falls, gantries, cranes, forklifts, etc. necessary for the disassembly and reassembly work and the required qualified personnel to operate the necessary rigging equipment.

Copyright

This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.

Trademarks

All trademarks referenced in this document are the trademarks of their respective owners.

Revision History

• Refrigerant used in purge changed to R-513A

• Running edits

CVHH-SVX001G-EN

Table of Contents

Unit Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Compressor Nameplate . . . . . . . . . . . . . . . . . . . 9

Pressure Vessel Nameplates. . . . . . . . . . . . . . . 9

Model Number Descriptions. . . . . . . . . . . . . . . 11

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

ASHRAE Standard 15 Compliance . . . . . . . . 12

Unit Shipment. . . . . . . . . . . . . . . . . . . . . . . . . . . 12

General Information . . . . . . . . . . . . . . . . . . . . . 12

Installation Requirements and

Contractor Responsibilities . . . . . . . . . . . . . . . 13

Storage Requirements . . . . . . . . . . . . . . . . . . . 14

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . 16

Unit Clearances and Weights . . . . . . . . . . . . . . 17

Recommended Unit Clearances. . . . . . . . . . . 17

General Weights. . . . . . . . . . . . . . . . . . . . . . . . . 18

Weights (lb) . . . . . . . . . . . . . . . . . . . . . . . . . 18

Weights (kg) . . . . . . . . . . . . . . . . . . . . . . . . . 19

Installation: Mechanical . . . . . . . . . . . . . . . . . . . 22

Operating Environment . . . . . . . . . . . . . . . . . . 22

Foundation Requirements . . . . . . . . . . . . . . . . 22

Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Standard Chiller Lift . . . . . . . . . . . . . . . . . . 22

Special Lift Requirements. . . . . . . . . . . . . 24

Unit Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Isolation Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Spring Isolators . . . . . . . . . . . . . . . . . . . . . . . . . 24

Leveling the Unit . . . . . . . . . . . . . . . . . . . . . . . . 26

Installation: Water Piping . . . . . . . . . . . . . . . . . . 28

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . 28

Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . 28

Valves—Drains and Vents . . . . . . . . . . . . . . . . 28

Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Required Flow-Sensing Devices. . . . . . . . . . . 29

Water Flow Detection Controller and

Sensor—ifm efector . . . . . . . . . . . . . . . . . . 29

Evaporator and Condenser Water

Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Water Piping Connections . . . . . . . . . . . . . . . . 32

Waterbox Locations . . . . . . . . . . . . . . . . . . . . . 32

Grooved Pipe Coupling . . . . . . . . . . . . . . . . . . 33

Flange-connection Adapters . . . . . . . . . . . . . . 33

Victaulic Gasket Installation . . . . . . . . . . . . . . 34

Screw-Tightening Sequence for Water

Piping Connections . . . . . . . . . . . . . . . . . . . . . . 35

Flanges with 8 or 12 Screws. . . . . . . . . . . 35

Flanges with 16 or 20 Screws . . . . . . . . . 35

Pressure Testing Waterside Piping . . . . . . . . 35

Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Refrigerant Vent Line . . . . . . . . . . . . . . . . . . . . 36

General Requirements. . . . . . . . . . . . . . . . 36

Purge Discharge . . . . . . . . . . . . . . . . . . . . . 36

Vent Line Materials. . . . . . . . . . . . . . . . . . . 36

Vent Line Sizing. . . . . . . . . . . . . . . . . . . . . . 36

Vent Line Installation. . . . . . . . . . . . . . . . . . . . . 37

Trane RuptureGuard . . . . . . . . . . . . . . . . . . . . . 39

General Information. . . . . . . . . . . . . . . . . . 39

Connection to External Vent Line and

Drip Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Vent Line Sizing Reference . . . . . . . . . . . . . . . 40

Insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Unit Insulation Requirements . . . . . . . . . . . . . 45

Insulation Thickness Requirements . . . . . . . 45

Factory Applied Insulation . . . . . . . . . . . . 45

Installation: Controls . . . . . . . . . . . . . . . . . . . . . . 47

UC800 Specifications . . . . . . . . . . . . . . . . . . . . 47

Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 47

Wiring and Port Descriptions. . . . . . . . . . 47

Communication Interfaces . . . . . . . . . . . . 48

Rotary Switches . . . . . . . . . . . . . . . . . . . . . 48

LED Description and Operation. . . . . . . . 48

Installing the Tracer AdaptiView

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Adjusting the Tracer AdaptiView Display

Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Electrical Requirements . . . . . . . . . . . . . . . . . . . 53

CVHH-SVX001G-EN 5

Installation Requirements . . . . . . . . . . . . . . . . 53

Electrical Requirements . . . . . . . . . . . . . . . . . . 53

Trane-supplied Remote Starter

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Customer-supplied Remote Starter

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Current Transformer and Potential

Transformer Wire Sizing . . . . . . . . . . . . . . . . . 57

Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . 58

Three-Phase Power . . . . . . . . . . . . . . . . . . . . . . 58

Circuit Breakers and Fused

Disconnects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

CE for Control Power Transformer

Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

CE for Starter or Drive . . . . . . . . . . . . . . . . 60

Control Power Transformer

Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Power Factor Correction Capacitors

(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Interconnecting Wiring. . . . . . . . . . . . . . . . . . . 63

Starter to Motor Wiring (Remote-

Mounted Starters Only) . . . . . . . . . . . . . . . . . . 64

Ground Wire Terminal Lugs. . . . . . . . . . . 64

Terminal Clamps. . . . . . . . . . . . . . . . . . . . . 65

Wire Terminal Lugs . . . . . . . . . . . . . . . . . . 65

Bus Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Starter to Control Panel Wiring . . . . . . . . . . . 66

Medium Voltage Motor . . . . . . . . . . . . . . . . . . . . 68

Motor Terminal Box . . . . . . . . . . . . . . . . . . . . . 68

Motor Supply Wiring. . . . . . . . . . . . . . . . . . . . . 69

Motor Terminals . . . . . . . . . . . . . . . . . . . . . 69

Ground Wire Terminal Lug. . . . . . . . . . . . 70

CE for Medium Voltage Starter. . . . . . . . . . . . 70

System Control Circuit Wiring (Field

Wiring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Water Pump Interlock Circuits and Flow

Switch Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Chilled Water Pump . . . . . . . . . . . . . . . . . . 73

Chilled Water Proof of Flow . . . . . . . . . . . 73

Condenser Water Pump . . . . . . . . . . . . . . 73

Condenser Water Proof of Flow . . . . . . . 74

Sensor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 74

CWR—Outdoor Option . . . . . . . . . . . . . . . 76

Optional Control and Output

Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Optional Tracer Communication

Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Starter Module Configuration. . . . . . . . . . . . . 76

Schematic Wiring Drawings . . . . . . . . . . . . . . 76

Operating Principles . . . . . . . . . . . . . . . . . . . . . . . 77

General Requirements . . . . . . . . . . . . . . . . . . . 77

Cooling Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

CVHH 3-Stage Compressor . . . . . . . . . . . 77

CVHH 2-Stage Compressor . . . . . . . . . . . 77

Oil and Refrigerant Pump . . . . . . . . . . . . . . . . 78

Compressor Lubrication

System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Motor Cooling System . . . . . . . . . . . . . . . . . . . 81

Tracer AdaptiView Display . . . . . . . . . . . . . . . 81

RuptureGuard . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

EarthWise Purge. . . . . . . . . . . . . . . . . . . . . . . . . 81

General Information. . . . . . . . . . . . . . . . . . 81

Start-up and Shut-down . . . . . . . . . . . . . . . . . . . 86

Sequence of Operation. . . . . . . . . . . . . . . . . . . 86

Software Operation Overview

Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Start-up Sequence of Operation—

Wye-delta . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Power Up Diagram . . . . . . . . . . . . . . . . . . . 90

Ice Machine Control. . . . . . . . . . . . . . . . . . . . . . 90

Free Cooling Cycle . . . . . . . . . . . . . . . . . . . . . . . 92

Hot Water Control . . . . . . . . . . . . . . . . . . . . . . . 93

Control Panel Devices and Unit-Mounted

Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Unit Control Panel . . . . . . . . . . . . . . . . . . . 93

User-Defined Language

Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Unit Start-up and Shut-down

Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Daily Unit Start-up . . . . . . . . . . . . . . . . . . . 95

6 CVHH-SVX001G-EN

Seasonal Unit Start-up . . . . . . . . . . . . . . . 95

Daily Unit Shut-down . . . . . . . . . . . . . . . . 96

Seasonal Unit Shut-down. . . . . . . . . . . . . 96

EarthWise Purge. . . . . . . . . . . . . . . . . . . . . . . . . 96

Sequence of Operations . . . . . . . . . . . . . . 96

Air Removal . . . . . . . . . . . . . . . . . . . . . . . . 100

Pump-out Operating Sequence. . . . . . . 100

Carbon Tank and Regeneration

Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . 101

Recommended Maintenance . . . . . . . . . . . . . 105

Record Keeping Forms . . . . . . . . . . . . . . . . . . 105

Normal Operation . . . . . . . . . . . . . . . . . . . . . . 106

Recommended Compressor Oil

Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Leak Checking Based on Purge Pump

Out Time . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Recommended System

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . 109

Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . 109

Waterbox and Tubesheet Protective

Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Sacrificial Anodes . . . . . . . . . . . . . . . . . . . 109

RuptureGuard Maintenance . . . . . . . . . . . . . 110

EarthWise Purge. . . . . . . . . . . . . . . . . . . . . . . . 110

Maintenance . . . . . . . . . . . . . . . . . . . . . . . 110

Waterbox Removal and

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 114

Torque Requirements and Waterbox

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Screw-Tightening Sequence for

Waterboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Evaporator Waterbox Covers . . . . . . . . 116

Condenser Waterbox Covers. . . . . . . . . 116

Heat Recovery Condenser Waterbox

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Appendix A: Forms and Check

Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Unit Start-up/Commissioning. . . . . . . . . . . . 118

Appendix B: CenTraVac ™ Chiller

Installation Completion and Request for

Trane Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Appendix C: CVHH CenTraVac ™ Chiller

Start-up Tasks to be Performed by

Trane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Appendix D: CVHH CenTraVac ™ Chiller

Annual Inspection List . . . . . . . . . . . . . . . . . . . . 123

Appendix E: CVHH CenTraVac ™ Chiller

Operator Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

CVHH-SVX001G-EN 7

8

Unit Nameplate

The unit nameplate is located on the left side of the control panel. A typical unit nameplate is illustrated in the following figure and contains the following information:

• Unit model and size descriptor

• Unit electrical requirements

• Correct operating charge and refrigerant type

• Unit test pressures and maximum operating pressures

• Unit literature specific chiller identity. Always provide this serial number when calling for service or during parts identification.

e M od Nu mb the unit as built for service purposes. It identifies the selections of variable unit features required when ordering replacements parts or requesting service.

separate number found on the starter.

Bllo ™ chiller models are defined and built using the Product

Definition and Selection (PDS) system. This system describes the product offerings using a product coding block which is made up of feature categories and codes that identify all characteristics of a unit.

Figure 1. Typical unit nameplate

CVHH-SVX001G-EN

Compressor Nameplate

The compressor assembly has a separate model number which is required to identify internal and external compressor parts. The model number begins with “CCHH” and the nameplate is located on the foot of the volute.

Figure 2. Compressor nameplate

TRANE

MODEL NO.

SERIAL NO.

MADE IN USA

SALES ORDER

X39002458010B nameplate will be intentionally left blank.

Pressure Vessel Nameplates

Figure 3.

ASME nameplate (all dimensions are metric)

C A D

B

4935 HTRC

939 STD

290 10

CD-001

290 10

290 10

16 6

DETAIL A

CONDENSER

75 10

34 6

2614

DETAIL C

OIL TANK

75 10

1131

DETAIL B

ECONOMIZER

75 10

DETAIL D

EVAPORATOR

789

CVHH-SVX001G-EN 9

Figure 4. PED nameplate (all dimensions are metric)

B

A

D

CD-001

C

CENTERED

1131

DETAIL A

ECONOMIZER

939

DETAIL B

CONDENSER

2735

50,8

50,8 4

12,7

4

DETAIL C

OIL TANK

25,4

DETAIL D

EVAPORATOR

789

10 CVHH-SVX001G-EN

Model Number Descriptions

CVHH CenTraVac Chiller Description

Digit 32 — Control: Enhanced Protection

Digit 1, 2 — Simplex CenTraVac ™ Chiller

Digit 3 — Direct Drive

Digit 4 — Development Sequence

Digit 34 — Tracer ® Communication

Interface

Digit 35 — Special Options

Digit 5, 6, 7 — Nominal Total Compressor

Tonnage

Digit 8 — Unit Motor Voltage

Digit 36 — Control: Water Flow Control

Digit 37 — Control: Chilled Water Reset

Digit 9 — Unit Type

Digit 33 — Control: Extended Operation

Digit 10, 11 — Design Sequence

Digit 12 — Manufacturing Location

Digit 13 — Hot Gas Bypass (HGB)

Digit 14 — Starter Type

Digit 38 — Control: Heat Recovery/

Auxiliary Temperature Sensors

Digit 39 — Industrial Chiller Package

(INDP)

Digit 40 — Control Power Transformer

(CPTR)

Digit 41 — Thermal Dispersion Water

Flow Proving

Digit 42 — Compressor Motor Frame Size

Digit 15 — Control Enclosure

CCHH Centrifugal Compressor

Description

The compressor assembly has a separate model number which is required to identify internal and external compressor parts. The model number begins with “CCHH” and the nameplate is located on the foot of the volute.

Digit 1, 2 — Unit Function

Digit 3 — Drive

Digit 4 — Development Sequence

Digit 5, 6, 7 — Nominal Total Compressor

Tonnage

Digit 8 — Compressor Motor Voltage

Digit 9 — Compressor Motor Frame Size

Digit 10, 11 — Design Sequence

Digit 12 — Manufacturing Location

Digit 16 — Evaporator Shell Size

Digit 17 — Evaporator Tube Bundle

Digit 18 — Evaporator Tubes

Digit 19 — Evaporator Waterbox

Digit 20 — Condenser Shell Size

Digit 13, 14, 15, 16 — Compressor Motor

Power (kW)

Digit 17, 18, 19, 20 — First Stage

Compressor Impeller (IMP1)

Digit 21, 22, 23, 24 — Second Stage

Compressor Impeller (IMP2)

Digit 25, 26, 27, 28 — Third Stage

Compressor Impeller (IMP3)

Digit 29 — Motor and Terminal Board

Configuration

Digit 30 — Resistant Temperature

Detector

Digit 21 — Condenser Tube Bundle

Digit 22 — Condenser Tubes

Digit 23 — Condenser Waterbox

Digit 24 — Auxiliary Condenser Size and

Waterbox

Digit 25, 26 — Evaporator Orifice Size

Digit 27, 28 — Economizer Orifice Size

Digit 29, 30 — Condenser Orifice Size

Digit 31 — Unit Option

CVHH-SVX001G-EN 11

Pre-Installation

ASHRAE Standard 15

Compliance

Trane recommends that indoor CenTraVac ™ chiller installations fully meet or exceed the guidelines of the current version of ASHRAE Standard 15, in addition to any applicable national, state, or local requirements.

This typically includes:

• A refrigerant monitor or detector that is capable of monitoring and alarming within the acceptable exposure level of the refrigerant, and that can actuate mechanical ventilation.

• Audible and visual alarms, activated by the refrigerant monitor, inside the equipment room and outside of every entrance.

• The equipment room should be properly vented to the outdoors, using mechanical ventilation that can be activated by the refrigerant monitor.

• The purge discharge and the rupture disk must be properly piped to the outdoors.

• If required by local or other codes, a self-contained breathing apparatus should be available in close proximity to the equipment room.

For the USA, refer to the latest copy of ASHRAE

Standard 15 for specific guidelines. Trane assumes no responsibility for any economic, health, or environmental issues that may result from an equipment room’s design or function.

Unit Shipment

Inspect unit while it is still on the truck for any shipping damage. The chiller ships shrink-wrapped in a 0.010-in.

(0.254 mm) recyclable film protective covering. Do NOT remove shrink-wrap for inspection! Inspect for damage to the shrink-wrap and determine if physical damage has occurred.

Each chiller ships from the factory as a hermetically assembled package; it is factory-assembled, -wired, and -tested. All openings except for the waterbox vent and drain holes are covered or plugged to prevent contamination during shipment and handling.

“Unit

Components,” p. 16

shows an illustration of a typical unit and its components. As soon as the unit arrives at the job site, inspect it thoroughly for damage and material shortages. In addition:

1. Verify the hermetic integrity of the unit by checking the chiller pressure for an indication of holding charge pressure.

2. To prevent damaging moisture from entering the unit and causing corrosion, each chiller is pressurized with 3 to 5 psig (20.7 to 34.5 kPaG) of dry nitrogen before shipment.

12 approximately 5 psig (34.5 kPaG) at 72°F (22.2°C).

Place a gauge on the access valve provided

(indicated by arrow and circle in the following figure) on the refrigerant pump discharge line to verify the holding charge. This access valve is located on the front of the oil tank, which is at the right rear corner of the chiller. If the charge has escaped, contact your local Trane sales office for instructions.

3. The loose parts box and isolator pads ship on top of the control panel box.

4. Check the oil sump sight glasses to verify that the sump was factory-charged with 21 gallons (79.5 L) of oil. The oil level should be visible to about halfway in the top sight glass. If no oil level is visible, contact your local Trane sales office.

block oil tank serviceability.

Figure 5. Refrigerant pump discharge line access valve

General Information

Regulations regarding waste handling are constantly changing. To ensure that personnel are in compliance with the latest local, state, and federal regulations, contact your local waste management office for the proper procedures on handling, disposal, transporting,

CVHH-SVX001G-EN

and storage of oil, oil filters, refrigerant filters, and filter dryer cores.

Installation Requirements and

Contractor Responsibilities

A list of the contractor responsibilities typically associated with the unit installation process is provided.

de atth eq pm shrink-wrap covering during storage.

Type of Requirement

Foundation

Rigging

Disassembly/Reassembly

(as required)

Isolation

Electrical

Trane Supplied

Trane Installed

Trane Supplied

Field Installed

Field Supplied

Field Installed

• Meet foundation requirements

• Safety chains

• Clevis connectors

• Lifting beam

• Trane will perform or have direct on-site supervision of the disassembly and reassembly work (contact your local Trane office for pricing)

• Isolation pads or spring isolators

• Isolation pads or spring isolators

• Optional spring isolators, when required, are installed by others; do NOT overload springs and do

NOT install isolation springs if they block serviceable parts such as the oil tank system, service valves, etc.

• Circuit breakers or fusible disconnects (optional)

• Electrical connections to unit-mounted starter

(optional)

• Circuit breakers or fusible disconnects (optional)

• Unit-mounted starter

(optional)

• Power factor correction capacitors (PFCCs)

(optional)

• Jumper bars

• Electrical connections to remote-mounted starter

(optional)

• Wiring sizes per submittal and National Electric Code

(NEC) or local codes

• Temperature sensor

(optional outdoor air)

• PFCCs (remote mounted starter optional only)

• Terminal lugs

• Flow switches (may be field supplied); for installation instructions for the ifm efector ® flow detection controller and sensor, refer to

“Water

Flow Detection

Controller and Sensor— ifm efector,” p. 29

or

Trane literature that shipped with the device

• Ground connection(s)

• Jumper bars

• BAS wiring (optional)

• Inter-processor communication (IPC) wiring (AFD and remote-mounted starters only)

• Control voltage wiring (AFD and remote-mounted starters only)

• Oil pump interlock wiring (AFD and remote mounted starters only)

• Remote-mounted starter (optional) • High condenser pressure interlock wiring (AFD and remote-mounted starters only)

• Chilled water pump contactor and wiring including interlock

• Condenser water pump contactor and wiring including interlock

• Option relays and wiring

CVHH-SVX001G-EN 13

Type of Requirement

Trane Supplied

Trane Installed

Trane Supplied

Field Installed

Field Supplied

Field Installed

• Taps for flow sensing devices

• Taps for thermometers and gauges

Water piping

• Flow sensing devices

(may be field supplied)

• Thermometers

• Strainers (as required)

• Water flow pressure gauges

• Isolation and balancing valves in water piping

• Vents and drain on waterbox valves (one each per pass)

• Pressure relief valves (for waterboxes as required)

Relief

• Rupture disk assembly

• RuptureGuard ™

(optional)

• Vent line and flexible connector and vent line from rupture disk to atmosphere

• Insulation

Insulation • Insulation (optional)

Water Piping Connection

Components

Flanged (optional)

Flanged (optional)

• Victaulic ® to flange adapter for 150 psig

(1034.2 kPaG) waterboxes

• Chiller feet insulation

Victaulic

®

Victaulic ® coupling for 150 psig (1034.2 kPaG) and

300 psig (2068.4 kPaG) waterboxes

Fasteners for flanged-type connections (optional)

Other Materials

• Material and equipment to perform leak testing

• Dry nitrogen (8 psig [55.2 kPaG] maximum per machine as needed)

“Appendix B: CenTraVac ™

Chiller Installation

Completion and Request for Trane Service,” p. 119

(CTV-ADF001*-EN; refer to

“Appendix A: Forms and

Check Sheets,” p. 118

)

• To be completed by installing contractor prior to contacting Trane for start-up

Chiller start-up commissioning (a)

• Trane, or an agent of

Trane specifically authorized to perform start-up of Trane ® products

Post-commissioning transport of empty refrigerant containers for return or recycling

(a)

• Move empty refrigerant containers to an easily accessible point of loading

Start-up must be performed by Trane or an agent of Trane specifically authorized to perform start-up and warranty of Trane ® products. Contractor shall provide Trane (or an agent of Trane specifically authorized to perform start-up) with notice of the scheduled start-up at least two weeks prior to the scheduled start-up.

Storage Requirements

•• D

•• D o n ag e tto

14 CVHH-SVX001G-EN

Less than 1 month

Location requirements:

• Solid foundation

• Vibration free

• Dry

• Temperature range -40°F to 158°F

(-40°C to 70°C)

1–6 months

Location requirements:

• Solid foundation

• Vibration free

• Dry

• Temperature range -40°F to 158°F

(-40°C to 70°C)

Greater than 6 months

Location requirements:

• Solid foundation

• Vibration free

• Dry

• Temperature range -40°F to 158°F

(-40°C to 70°C)

• Do not remove any plastic coverings

• Do not charge the chiller with refrigerant

• If additional refrigerant is on site, follow manufacturer’s storage requirements

• Verify dry nitrogen pressure using gauge located on the evaporator shell reads

3 to 5 psig (20.7 to 34.5 kPaG)

• Notify the local Trane office if charge has escaped

• Do not operate purge unit

• Do not remove any plastic coverings • Do not remove any plastic coverings

• Do not charge the chiller with refrigerant • Do not charge the chiller with refrigerant

• If additional refrigerant is on site, follow manufacturer’s storage requirements

• If additional refrigerant is on site, follow manufacturer’s storage requirements

• Verify dry nitrogen pressure using gauge located on the evaporator shell reads

3 to 5 psig (20.7 to 34.5 kPaG)

• Verify dry nitrogen pressure using gauge located on the evaporator shell reads 3 to 5 psig

(20.7 to 34.5 kPaG)

• Notify the local Trane office if charge has escaped

• Notify the local Trane office if charge has escaped

• Do not operate purge unit • Do not operate purge unit

• Verify waterbox and tube bundles are clean and dry

• Verify waterbox and tube bundles are clean and dry

• Conduct an oil analysis and verify no oil breakdown (a)

• Repeat yearly

• Replace oil if breakdown has occurred

(a)

• If no oil analysis program has been followed, replace oil prior to start-up

If the chiller will be stored for more than six months after production, contact your local Trane Service Agency for required extended storage actions to minimize impact to the chiller and preserve the warranty.

CVHH-SVX001G-EN 15

Unit Components

designated as the front side of the unit.

Figure 6. Typical CVHH CenTraVac ™ chiller

-

4

1

2

3

0

6

9

5

0

7

8

1. Suction Elbow

2. Compressor

3. Terminal Box

4. Control Panel

5. Condenser

6. Motor Housing

7. Economizer

8. Oil Tank Assembly

9. Purge

10. Evaporator

11. Display Panel

16 CVHH-SVX001G-EN

Unit Clearances and Weights

Recommended Unit Clearances

Adequate clearances around and above the chiller are required to allow sufficient access for service and maintenance operations. Specific unit clearance requirements are indicated in the submittal package provided for your unit.

• Do NOT install piping or conduit above the compressor motor assembly or behind the suction elbow of the unit.

• Minimum vertical clearance above the unit is 3 ft

(92 cm).

Figure 7.

Clearance requirements

• Use a housekeeping pad to provide better service clearances; refer to submittal for more information.

Per National Electric Code (NEC) Article 110: Unit mounted starters from 0 to 600V require a 42 inch

(107 cm) clearance, 601 to 2500V require a 48 inch

(122 cm) clearance, and 2501 to 9000V require a 60 inch

(152 cm) clearance. Refer to NEC and local electrical codes for starter and control panel clearance requirements.

18 in. (46 cm)

Economizer

Condenser

D

Evaporator

Motor

Right-hand tube pull shown, apply tube pull clearance dimension to left end for left-hand tube pull.

E

A

These dimensions per

NEC Article 110

3 ft. (92 cm)

Optional unit-mounted starter

B

C

Table 1.

Clearance requirements

A

Shell Combo

100M/100M

100M/10HM

100L/100L

130M/130M

130M/13HM in.

84

84

84

88

88 cm

213

213

213

224

224

CVHH-SVX001G-EN in.

166

166

186

166

166

B cm

422

422

422

422

422 in.

416

416

457

420

420

C cm

1057

1057

1161

1067

1067 in.

12

31

12

29

31

D cm

30

79

30

74

79 in.

122

118

122

109

123

E cm

310

300

310

277

312

17

Table 1.

Clearance requirements (continued)

Shell Combo

160M/200M

160M/20HM

200L/200L

200L/20HL

200L/220L

220L/220L

220L/22HL in.

96

96

107

107

107

120

120

A cm

244

244

272

272

272

305

305 in.

166

166

186

186

186

186

186

B cm

422

422

472

472

472

472

472 in.

428

428

479

479

480

493

492

C cm

1087

1087

1217

1217

1219

1252

1250 in.

37

36

34

37

37

38

42

Note: All dimensions are approximate; refer to the unit submittal package for exact dimensions for your unit.

D cm

94

91

86

94

94

97

107

General Weights

Weights (lb)

in.

112

128

111

131

120

118

143

E should be used for general information only. Trane does not recommend using this weight information for considerations relative to chiller handling, rigging, or placement. The large number of variances between chiller selections drives variances in chiller weights that are not recognized in these tables. For specific weights for your chiller, refer to your submittal package.

Table 2.

Representative weights, 60 Hz chillers (lb)

Model

CVHH

Comp Size

NTON

900–1200

900–1200

900–1200

900–1200

900–1200

900–1200

900–1200

900–1200

CPKW

1228

1228

1340

1340

1340

1340

1340

1340

Evap Size

EVSZ

100M

100L

100M

130M

130M

160M

200L

220L

Cond Size

CDSZ

100M

100L

10HM

130M

13HM

200M

220L

220L

Weights without Starters

Operating

47451

49252

54999

52868

62184

63653

71963

79082

Shipping

41071

42368

47798

44894

53398

53621

58931

64664

1500–1700

1500–1700

1340

1340

200L

200L

200L

20HL

70921

80262

59137

67562

1500–1700 1340 220L 220L 79082 64664

1500–1700 1340 220L 22HL 93396 78060

Notes:

1 .

TECU tubes, 0.028 in. tube wall thickness.

2 .

300 psig marine waterboxes.

3 .

Heaviest possible bundle and motor combination.

4 .

Operating weights assume the largest possible refrigerant charge.

5 .

Industrial Control Panel (INDP) option, add 50 lb.

6 .

Control Power Transformer (CPTR) option, add 280 lb.

7 .

Supplemental Motor Protection (SMP) option, add 500 lb.

8 .

To calculate the maximum chiller weight with starter/drive, add the starter/AFD weight from the following table (maximum weights, unit-mounted starters/AFDs [lb]) to the chiller maximum weight from this table.

cm

285

325

282

333

305

300

363

18 CVHH-SVX001G-EN

Table 3.

Representative weights, 50Hz chillers (lb)

Model

CVHH

Comp Size

NTON

950–1050

950–1050

950–1050

950–1050

950–1050

950–1050

950–1050

950–1050

CPKW

1023

1023

1023

1023

1023

1023

1023

1023

Evap Size

EVSZ

100M

100L

100M

130M

130M

160M

200L

220L

Cond Size

CDSZ

100M

100L

10HM

130M

13HM

200M

220L

220L

Weights without Starters

Operating

49024

50824

56723

54592

63908

65377

73687

80806

Shipping

42643

43940

49522

46618

55122

55345

60655

66388

1550

1550

1550

1023

1023

1023

200L

200L

220L

200L

20HL

220L

72345

81686

80506

60561

68986

66088

1550 1023 220L 22HL 94820 79484

Notes:

1 .

TECU tubes, 0.028 in. tube wall thickness.

2 .

300 psig marine waterboxes.

3 .

Heaviest possible bundle and motor combination.

4 .

Operating weights assume the largest possible refrigerant charge.

5 .

Industrial Control Panel (INDP) option, add 50 lb.

6 .

Control Power Transformer (CPTR) option, add 280 lb.

7 .

Supplemental Motor Protection (SMP) option, add 500 lb.

8 .

To calculate the maximum chiller weight with starter/drive, add the starter/AFD weight from the following table (maximum weights, unit-mounted starters/AFDs [lb]) to the chiller maximum weight from this table.

Weights (kg)

Table 4.

Maximum weights, unit-mounted starters/

Adaptive Frequency ™ Drives (AFDs) (lb)

Low Voltage (less than 600 volts)

Adaptive Frequency Drive (less than

600 volts)

Medium Voltage (2300–6600 volts)

Wye-delta

Solid State

900 amp

1210 amp

Across-the-line

Primary Reactor

Autotransformer

Note: All weights are nominal and ±10%.

557

557

3000

3000

652

1602

1702 should be used for general information only. Trane does not recommend using this weight information for considerations relative to chiller handling, rigging, or placement. The large number of variances between chiller selections drives variances in chiller weights that are not recognized in these tables. For specific weights for your chiller, refer to your submittal package.

CVHH-SVX001G-EN 19

Table 5.

Representative weights, 60 Hz chillers (kg)

Model

CVHH

Comp Size

NTON

900–1200

900–1200

900–1200

900–1200

900–1200

900–1200

900–1200

900–1200

CPKW

1228

1228

1340

1340

1340

1340

1340

1340

Evap Size

EVSZ

100M

100L

100M

130M

130M

160M

200L

220L

Cond Size

CDSZ

100M

100L

10HM

130M

13HM

200M

220L

220L

Weights without Starters

Operating

21523

22340

24947

23981

28206

28873

32642

35871

Shipping

18629

19218

21681

20364

24221

24322

26731

29331

1500–1700

1500–1700

1500–1700

1340

1340

1340

200L

200L

220L

200L

20HL

220L

32169

36406

35871

26824

30646

29331

1500–1700 1340 220L 22HL 42364 35407

Notes:

1 .

TECU tubes, 0.71 mm tube wall thickness.

2 .

2068.4 kPaG marine waterboxes.

3 .

Heaviest possible bundle and motor combination.

4 .

Operating weights assume the largest possible refrigerant charge.

5 .

Industrial Control Panel (INDP) option, add 23 kg.

6 .

Control Power Transformer (CPTR) option, add 127 kg.

7 .

Supplemental Motor Protection (SMP) option, add 227 kg.

8 .

To calculate the maximum chiller weight with starter/drive, add the starter/AFD weight from the following table (maximum weights, unit-mounted starters/AFDs [kg]) to the chiller maximum weight from this table.

Table 6.

Representative weights, 50 Hz chillers (kg)

Model

CVHH

Comp Size

NTON

950–1050

950–1050

950–1050

950–1050

950–1050

950–1050

950–1050

950–1050

1550

CPKW

1023

1023

1023

1023

1023

1023

1023

1023

1023

Evap Size

EVSZ

100M

100L

100M

130M

130M

160M

200L

220L

200L

Cond Size

CDSZ

100M

100L

10HM

130M

13HM

200M

220L

220L

200L

Weights without Starters

Operating

22237

23053

25729

24763

28988

29655

33424

36653

32815

Shipping

19343

19931

22463

21146

25003

25104

27513

30113

27470

1550

1550

1023

1023

200L

220L

20HL

220L

37052

36517

31292

29977

1550 1023 220L 22HL 43010 36053

Notes:

1 .

TECU tubes, 0.71 mm tube wall thickness.

2 .

2068.4 kPaG marine waterboxes.

3 .

Heaviest possible bundle and motor combination.

4 .

Operating weights assume the largest possible refrigerant charge.

5 .

Industrial Control Panel (INDP) option, add 23 kg.

6 .

Control Power Transformer (CPTR) option, add 127 kg.

7 .

Supplemental Motor Protection (SMP) option, add 227 kg.

8 .

To calculate the maximum chiller weight with starter/drive, add the starter/AFD weight from the following table (maximum weights, unit-mounted starters/AFDs [kg]) to the chiller maximum weight from this table.

20 CVHH-SVX001G-EN

Table 7.

Maximum weights, unit-mounted starters/

Adaptive Frequency ™ Drives (AFD) (kg)

Low Voltage (less than 600 volts)

Adaptive Frequency Drive (less than 600 volts)

Wye-delta

Solid State

900 amp

1210 amp

253

253

1361

1361

Table 7. Maximum weights, unit-mounted starters/

Adaptive Frequency ™ Drives (AFD) (kg) (continued)

Medium Voltage (2300–6600 volts)

Across-the-line

Primary Reactor

Autotransformer

Note: All weights are nominal and ±10%.

296

727

772

CVHH-SVX001G-EN 21

Installation: Mechanical

Operating Environment

• The standard chiller is designed for indoor use only and as such has NEMA

Type 1 or IP 20 enclosures.

• For chillers in unheated equipment rooms, contact your local Trane Service

Agency for methods to ensure that the oil temperature is maintained suitable for proper operation of the chiller.

diissssiip atte da ma ess e xcce na biilliitty

CD HG

VH S C

Rigging

Lifting is the recommended method for moving chillers. Suggested lifting arrangements for standard units are described in

“Standard Chiller Lift,” p. 22

.

otte ™ chillers must be at least long.

da ma an d ssh h.. A djju orr sslliin gss)) m orr sslliin gss)),, h o iim prro eq uiip ntt rro om

To ensure that electrical components operate properly, do NOT locate the chiller in an area exposed to dust, dirt, corrosive fumes, or excessive heat and humidity.

The ambient temperature range for chiller operation is

34°F to 104°F (1.1°C to 40°C).

Foundation Requirements

Chiller mounting surface must be:

• rigid non-warping mounting pads or a concrete foundation, and

• able to support the chiller at its full operating weight (including completed piping and full operating charges of refrigerant, oil, and water).

For proper unit operation, the chiller must be level within 1/16 in. (1.6 mm) over its length and width when set into place on the mounting surface.

“Weights

(lb),” p. 18

and

“Weights (kg),” p. 19

show approximate weights for various chiller sizes and options in pounds and kilograms, respectively.

submittal package.

equipment problems resulting from an improperly designed or constructed foundation.

22 urriin g rriig

Standard Chiller Lift

de h o eq uiip

1. Insert clevis connections at the points indicated in the following figure. A 2.5 in. (63.5 mm) diameter lifting hole is provided at each of these points.

2. Attach the lifting chains or cables.

3. Once the lifting cables are in place, attach a safety chain or cable between the first-stage casing of the compressor and the lifting beam.

safety cable; the cable is used only to prevent the unit from rolling during the lift.

CVHH-SVX001G-EN

4. Position isolator pads or spring isolators beneath the chiller feet (refer to

“Unit Isolation,” p. 24

for instructions).

isolator manufacturer, being careful to not damage isolator adjustment screw.

5. Once the isolators are in place, lower the chiller— working from end to end—in small increments to maintain stability.

6. When lift is complete, detach the clevis connections and safety chain.

Figure 8. Typical rigging arrangements

15 feet

(4.6 m) minimum effective length

Safety chain or cable

Jack slots

CVHH-SVX001G-EN 23

Special Lift Requirements

da ma e..

eq uiip ess,, rre mo an y a o--e nd n d urriin uiip me oiill tta nkk

If the chiller cannot be moved using a standard chiller lift, consider the following:

• When job site conditions require rigging of the chiller at an angle greater than 45° from horizontal

(end-to-end), the unit may require removal of the compressor. Contact Trane or an agent of Trane specifically authorized to perform start-up and warranty of Trane ® products regarding the disassembly and reassembly work. For more information, refer to

“Factory Warranty

Information,” p. 4

.

dowel-pinning the compressor and removing it from the unit. Contact Trane or an agent of

Trane specifically authorized to perform startup and warranty of Trane ® products for specific rigging instructions. Do NOT attempt to rotate the chiller onto its side.

• When lifting the chiller is either impractical or undesirable, attach cables or chains to the jacking slots shown in the figure in

“Standard Chiller

Lift,” p. 22

; then push or pull the unit across a smooth surface. Should the chiller be on a shipping skid, it is not necessary to remove the skid from the chiller before moving it into place.

• If removal of the compressor or economizer assembly is necessary to move the chiller to the

24 operating location, contact Trane. Also refer to

“Factory Warranty Information,” p. 4 .

Unit Isolation

To minimize sound and vibration transmission through the building structure and to ensure proper weight distribution over the mounting surface, always install isolation pads or spring isolators under the chiller feet.

otte

“Isolation

Pads,” p. 24 ) are provided with each chiller

unless spring isolators are specified on the sales order.

Specific isolator loading data is provided in the unit submittal package. If necessary, contact your local

Trane sales office for further information.

pads or spring isolators, remember that the control panel side of the unit is always designated as the front side of the unit.

Isolation Pads

When the unit is ready for final placement, position isolation pads (18-in. [457.2-mm] sides) end for end under the full length of the chiller leg. The pads measure 9 in. × 18 in. (228.6 mm x 457.2 mm) and on some units there may be small gaps between pads.

Pads are provided to cover entire foot.

Figure 9.

Isolation pad and dimensions

A

B

C

A = 3/8 in. (9.5 mm)

B = 18 in. (457.2 mm)

C = 9 in. (228.6 mm)

Remember that the chiller must be level within 1/16 in.

(1.6 mm) over its length and width after it is lowered onto the isolation pads. In addition, all piping connected to the chiller must be properly isolated and supported so that it does not place any stress on the unit.

Spring Isolators

Spring isolators should be considered whenever chiller installation is planned for an upper story location. Base isolator placement is shown in the following figure; also refer to the following table.

CVHH-SVX001G-EN

Figure 10.

Isolation spring placement

Isolator Configuration 1

2 4

Condenser

Width

Evaporator

1 3

Length

Origin:

Right front corner of evap right front foot

Isolator Configuration 2

2 4

Condenser

5

1

Evaporator

6

3

Evap

Width

Width

Length

Table 8.

Isolation spring placement

EVSZ

200L

220L

200L

220L

160M

200L

160M

100M

100L

130M

100M

130M

CDSZ

200L

220L

20HL

22HL

20HM

220L

200M

100M

100L

130M

10HM

13HM in.

112.2

119.4

132.3

142.5

127.3

112.3

106.4

104.1

104.1

109.3

118.2

123.4

Width cm

285.0

303.3

336.0

361.0

323.3

285.2

270.3

264.4

264.4

277.6

300.2

313.4

in.

67

74

67

74

61

67

61

Evap Width cm

170.2

188.0

170.2

188.0

154.9

170.2

154.9

Spring isolators typically ship assembled and ready for installation. To install and adjust the isolators properly, follow the provided instructions.

piped and charged with refrigerant and water.

such as the lubrication system with fieldinstalled devices such as spring isolators.

1. Position the spring isolators under the chiller as shown in the preceding figure. Ensure that each isolator is centered in relation to the tube sheet.

in.

180

160

180

160

160

160

180

180

180

160

180

160

Length cm

457.2

457.2

457.2

457.2

406.4

457.2

406.4

406.4

457.2

406.4

406.4

406.4

Isolator

Config

2

2

2

2

2

2

2

1

1

1

1

1

Origin to Center of Rear Pad in.

cm

105.7

268.5

112.9

125.8

136.0

120.8

105.8

99.9

97.6

97.6

102.8

111.7

116.9

286.8

319.5

345.4

306.8

268.7

253.7

247.9

247.9

261.1

283.7

296.9

Origin to Center of Middle Pad in.

cm

60.5

153.7

67.5

60.5

67.5

54.5

60.5

54.5

171.5

153.7

171.5

138.4

153.7

138.4

— not be identical. Compare the data provided in the unit submittal package to determine proper isolator placement.

2. Set the isolators on the sub-base; shim as necessary to provide a flat, level surface at the same elevation for the end supports.

isolator base plate; do NOT straddle gaps or small shims.

3. If required, screw the isolators to the floor through the slots provided, or cement the pads.

necessary unless specified.

CVHH-SVX001G-EN 25

4. If the chiller must be fastened to the isolators, insert cap screws through the chiller base and into holes drilled and tapped in the upper housing of each isolator.

below the underside of the isolator upper housing, or interfere with the adjusting screws. An alternative method of fastening the chiller to the isolators is to cement the neoprene pads.

5. Set the chiller on the isolators; refer to

“Standard

Chiller Lift,” p. 22 . The weight of the chiller will

force down the upper housing of each isolator, and could cause it to rest on the isolator’s lower housing (refer to the following figure).

6. Check the clearance on each isolator. If this dimension is less than 1/4 in. (6.35 mm) on any isolator, use a wrench to turn the adjusting screw one complete revolution upward.

(refer to

Step 5

), the top plate of each isolator moves down to compress the springs until either the springs support the load or the top plate rests on the bottom housing of the isolator. If the springs are supporting the load, screwing down on the adjusting screw (refer to

Step 7

) will raise the chiller.

7. Turn the adjusting screw on each of the remaining isolators to obtain the required minimum clearance of 1/4 in. (6.35 mm).

8. Once the minimum required clearance is obtained on each of the isolators, level the chiller by turning the adjusting screw on each of the isolators on the low side of the unit. Work from one isolator to the next.

16 in. (1.6 mm) over its length and width, and the clearance of each isolator must be at least 1/4 in.

(6.35 mm).

Figure 11. Chiller foot and isolator orientation

End View of Unit Side View of Unit

Center tube sheet support leg

Outside edge of tube sheet

Center of isolator spring

Note: The spring isolator must be centered in relation to the tube sheet.

Do not align the isolator with the flat part of the chiller foot since the tube sheet is often off center.

Note: The length of the isolator should be parallel to the leg.

in such a way that they could inhibit chiller servicing such as charging or evacuation, oil tank service, etc.

Leveling the Unit

The chiller must be set level within 1/16 in. (1.6 mm).

1. Measure and make a punch mark an equal distance up from the bottom of each foot of the chiller.

2. Suspend a clear plastic tube along the length of the chiller as shown in the following figure.

3. Fill the tube with water until the level aligns with the punch mark at one end of the chiller.

4. Check the water level at the opposite mark. If the water level does not align with the punch mark, use full length shims to raise one end of the chiller until the water level at each end of the tube aligns with the punch marks at both ends of the chiller.

5. Once the unit is level across its length, repeat the first three steps to level the unit across its width.

26 CVHH-SVX001G-EN

Figure 12.

Leveling the chiller method to level the unit.

2

1 incurred during handling or installation at the job site to the Trane sales office.

CVHH-SVX001G-EN 27

Installation: Water Piping

Overview

The following water piping circuits must be installed and connected to the chiller:

• Pipe the evaporator into the chilled water circuit.

• Pipe the condenser into the cooling tower water circuit.

• Optional: A heat-recovery condenser water circuit.

• Optional: An auxiliary condenser water circuit.

stress on the equipment. It is strongly recommended that the piping contractor does not run pipe closer than 3 ft (0.9 m) minimum to the equipment. This will allow for proper fit upon arrival of the unit at the job site. Any adjustment that is necessary can be made to the piping at that time. Expenses that result from a failure to follow this recommendation will NOT be paid by

Trane.

Piping suggestions for each of the water circuits listed above are outlined in

“Evaporator and Condenser

Water Piping,” p. 30 . General recommendations for the

installation of field-supplied piping components (e.g., valves, flow switches, etc.) common to most chiller water circuits are listed in the following sections.

Water Treatment

The use of untreated or improperly treated water in a

CenTraVac ™ chiller may result in inefficient operation and possible tube damage.

services of a qualified water treatment specialist to determine necessary water treatment. A label with a customer disclaimer note is affixed to each unit.

an y,, iiss rre eq uiip a 6 in. (16 cm) pipe, the tap would be at least 6 in. (16 cm) from any elbow, orifice, etc.

Valves—Drains and Vents

da ma ap e w he n iin an d ox ess..

1. Install field-supplied air vents and drain valves on the waterboxes. Each waterbox is provided with a

National Pipe Thread Female (NPTF) vent and drain connection; the openings are 3/4 in. (19.05 mm).

errb ox hy drro orr w atte

2. If necessary for the application, install pressurerelief valves at the drain connections on the evaporator and condenser waterboxes. To do so, add a tee with the relief valve attached to the drain valve. Follow local codes for determining if drain connection is large enough for relief devices.

To determine whether or not pressure relief valves are needed for a specific application, keep in mind that: a. Vessels with close-coupled shutoff valves may cause high potentially damaging hydrostatic pressures as fluid temperature rises.

b. Relief valves are required by American Society of Mechanical Engineers (ASME) codes when the waterside is ASME. Follow ASME guidelines or other applicable codes/local regulation to ensure proper relief valve installation.

Strainers

Pressure Gauges

Locate pressure gauge taps in a straight length of pipe.

Place each tap a minimum of one pipe diameter downstream of any elbow, orifice, etc. For example, for

28 ne om

CVHH-SVX001G-EN

Install a strainer in the entering side of each piping circuit to avoid possible tube plugging in the chiller with debris.

Required Flow-Sensing Devices

The ifm efector® flow detection controller and sensor

(refer to

“Water Flow Detection Controller and Sensor

—ifm efector,” p. 29 ) is used to verify evaporator and

condenser water flows.

If a customer-supplied flow sensing device is used to ensure adequate chiller flow protection, refer to the wiring diagrams that shipped with the unit for specific electrical connections.

Be sure to follow the manufacturer’s recommendations for device selection and installation.

Water Flow Detection Controller and

Sensor—ifm efector

an ® flow detection controller and sensor, use a marker to draw a line on the probe at 3.5 in.

(8.9 cm) from the end of the probe. Do NOT insert more than 3.5 in. (8.9 cm) of the probe length into the pipe. Refer to the following figure.

Figure 13.

Installation of ifm efector ® flow detection controller and sensor

If factory-provided, located in control panel.

Components:

A . E40174 – 1/2" NPT adapter (for flow probe)

B . SF6200 – Flow probe

C . SN0150 – Flow control monitor

D . E70231 – Combicon connectors (quantity 5)

4

F53003 – Din rail, 40mm length

3

Installation

1. Install adapter (A) into pipe.

2. Mount flow probe (B) into adapter (A).

3. Install DIN rail (F) into control cabinet.

4. Install control monitor (C) onto DIN rail (F).

Use a marker to draw a line

5. Connect cable (E) to flow probe (B), (hand tighten only).

wiring diagram.

from the probe end.

7. Wire relay outputs for flow, wire-break, and/or temperature monitoring, according to wiring diagram.

2

1

To wire the flow monitoring and wire-break monitoring relay outputs in series, use the wiring diagram at right.

Flow monitoring

Wire break monitoring

Temperature monitoring

Power-on delay time

Selection liquid / gas

Temperature monitoring can also be incorporated using terminals 10, 11, and 12.

Jumper

L

N

AC

Jumper control cabinet

3.5 in. (8.9 cm) of the probe length into the pipe.

1. Mount the 1/2-in. NPT adapter in a horizontal or vertical section of pipe. The maximum distance

CVHH-SVX001G-EN from the control panel must not exceed 29.5 ft (9 m)

(see item labeled “1” in the preceding figure). Allow at least five pipe diameters straight run of pipe upstream of the sensor location, and three pipe diameters straight run of pipe downstream of the sensor location.

sensor in the side of the pipe is preferred. In the case of a vertical pipe, mounting the sensor in a place where the water flows upwards is preferred.

2. Insert the flow sensor probe (see item labeled “2” in the preceding figure) through the 1/2-in. NPT adapter so that 3 to 3.5 in. (7.6 to 8.9 cm) of the probe’s length extends into the pipe. Tighten the 1/

2-in. NPT adapter as needed to prevent leakage and keep the probe from backing out under pressure.

en d..

otte ® sensor probe must be at least 1 in. (2.54 cm) away from any pipe wall. Do NOT insert more than 3.5 in. (8.9 cm) of the probe length into the pipe.

3. Install the Micro DC Cable by inserting it through the wire openings on the back side of the control panel (see item labeled “3” in the preceding figure).

Install the supplied Micro DC Cable (29.5 ft [9 m] in length) to the Flow Probe and hand-tighten the connector nut.

4. Plug the other end of the Micro DC Cable into the

Flow Control Monitor with the Combicon connector

(see item labeled “4” in the preceding figure). Refer to the following figure for cable wiring.

orr w he orr d am o u niitt d urriin g

29

low/no flow status.

Figure 14. ifm efector ® flow sensing device terminal connection

7

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote—are IP2X.

5. Apply power to the chiller control panel to verify the

Flow Control Monitor has power and the Low Volt

Broken Wire Relay light is NOT lit.

6. Remove all air from the piping circuit prior to adjusting the low water flow setpoint.

7. Reduce the water flow to the minimum allowable flow and adjust the Flow setting on the Flow

Control Monitor (see item labeled “7” in the following figure). Adjusting the “Flow” potentiometer clockwise (+) reduces the flow setting cutout and adjusting counterclockwise (-) increases the flow setting cutout.

efector ® control module has no effect in

Trane application. It is NOT necessary to make adjustments to the “Temp” potentiometer.

8. After the cutout setting is adjusted, the cutout setpoint will be indicated with a yellow light on the

Flow Control Monitor LED bar graph display. When the water flows are higher than the cutout, a green light will indicate proper flow status. If the flows fall below the cutout setpoint, a red light will indicate

30 da ma

Ev ap

•• F uiittss rre qu

•• F ue ntt ccy an d p ag essu

Evaporator and condenser proof of flow switches are required. These switches are used with control logic to confirm flow prior to starting a unit and to stop a running unit if flow is lost. For troubleshooting, a viewable diagnostic is generated if a proof of flow switch does not close when flow is required.

Evaporator and Condenser

Water Piping

The following two figures illustrate the recommended

(typical) water piping arrangements for the evaporator and condenser.

CVHH-SVX001G-EN

Figure 15.

Typical evaporator water piping circuit

2 1 7 3 5

2

9

2

4

Outlet

4

Inlet

6 8 2 3 5

1. Balancing valve.

2. Gate (Isolation) valve or ball valve.

3. Thermometer (if field supplied).

4. Waterbox nozzle connection.

5. Drain, vent, and anode.

6. Strainer.

7. Chilled water flow switch (4B4). Flow switch 4B4 may be installed in either the entering or leaving leg of the chilled water circuit.

8. Pump.

9. Pressure gauge. It is recommended to pipe the gauge between entering and leaving pipes. A shutoff valve on each side of the gauge allows the operator to read either entering or leaving water pressure.

Figure 16.

Typical condenser water piping circuits

Outlet

4 2 5

10

2

3 7 1 2 8

Inlet

4 5 3 2 9

1. Balancing valve.

2. Gate (isolation) valve or ball valve.

3. Thermometer (if field supplied).

4. Waterbox nozzle connection.

5. Drain, vent, and anode.

6. Strainer.

7. Condenser water flow switch (4B5). Flow switch

4B5 may be installed in either the entering or leaving leg of the water circuit.

8. Three-way valve (optional).

9. Condenser water pump.

10. Pressure gauge. It is recommended to pipe a single gauge between entering and leaving pipes.

CVHH-SVX001G-EN

6

• Some type of field-supplied temperature control device may be required to regulate the temperature of the heat-recovery condenser water circuit. For application recommendations, refer to Heat Recovery

Seminar (Part 2): Systems/Equipment (AM-

FND-8).

• Install a bypass valve system to avoid circulating water through the auxiliary shell when the unit is shut down.

• On multiple-pass condensers, entering condenser water must enter at the lowest nozzle.

Piping must be arranged and supported to avoid stress on the equipment. It is strongly recommended that the piping contractor does not run pipe closer than 3 ft

(0.9 m) minimum to the equipment. This will allow for proper fit upon arrival of the unit at the job site. Any adjustment that is necessary can be made to the piping at that time. Expenses that result from a failure to follow this recommendation will NOT be paid by Trane.

Water piping connection sizes and components are identified in the tables in

“Water Piping

Connections,” p. 32

and

“Grooved Pipe Coupling,” p.

33 . Remember that with many waterboxes, the

entering and leaving evaporator water can be piped to either waterbox connection when the tube bundles are split vertically. However, large evaporator waterboxes with entering and leaving connections not at the same level must be connected with the entering water at the bottom and the leaving water at the top.

Waterboxes with multiple pass arrangements utilize a baffle to separate the passes. These baffles are designed for a maximum pressure of 20 psid

(137.9 kPaD). If larger pressure drops are expected in the application, contact your local Trane representative to discuss special waterbox options.

with nameplate designation.

Field-provided isolation valves for the evaporator and condenser water lines should be installed upstream and downstream of the heat exchangers, and be installed far enough away from the chiller to also provide practical service isolation for flow sensing devices, field thermometers, flexible connectors, and any removable pipe spools.

Ensure that the evaporator water piping is clear; check it after the chilled water pump is operated but before initial chiller start-up. If any partial blockages exist, they can be detected and removed to prevent possible tube damage resulting from evaporator freeze-up or erosion.

For condenser and large evaporator connections, arrange the water piping so that the water supply enters the shell at the lower connection and exits from the top connection. Operational problems may result if

31

this piping is not correct. Some shells may be piped as desired since both connections are at the same level.

For applications that include an “infinite source” or

“multiple-use” cooling condenser water supply, install a valved bypass “leg” (optional) between the supply and return pipes. This valved bypass allows the operator to short-circuit water flow through the cooling condenser when the supply water temperature is too low.

maintained above 3 psid (20.7 kPaD) at all times.

Failure to do so could result in operating problems.

Water Piping Connections

All standard units use grooved-pipe connections.

These are grooved-end NSP (Victaulic ® style) pipe connections. Flanged connections are optional.

Piping joined using grooved type couplings, like all types of piping systems, requires proper support to carry the weight of pipes and equipment. The support methods used must eliminate undue stresses on joints, piping, and other components, allow movement where required, and provide for any other special requirements (i.e., drainage, etc.).

available for purchase from Trane Parts Service.

These sensor extension cables may be necessary if the waterboxes are changed or if the temperature sensors are moved out into the unit piping for better mixed temperature readings.

Table 9.

Water connection pipe sizes

Water

Passes

Evaporator

1-Pass

2-Pass

3-Pass

Condenser

1-Pass

2-Pass

Evaporator

Shell Size

100 130 160 200 220 400 440

Nominal Pipe Size (in.)

12

10

8

12

10

14

12

16

14

20

14

16

8 10 12 12

Nominal Pipe Size (in.)

20

12

10

14 — 16 24

12 — 14 14

Metric Pipe Size (mm)

24

1-Pass

2-Pass

DN300 DN300 DN350 DN400 DN500 DN400 DN500

DN250 DN250 DN300 DN350 DN350 — —

— 3-Pass

Condenser

DN200 DN200 DN250 DN300 DN300 —

Metric Pipe Size (mm)

1-Pass DN300 DN350 — DN400 DN600 —

2-Pass DN250 DN300 — DN350 DN350 —

DN600

32

Figure 17. Typical grooved pipe connection

Waterbox Locations

recovery waterboxes. Proper unit operation could be affected by repositioning heat recovery waterboxes. Contact CenTraVac ™

Chiller Technical Service for more information.

If necessary, the non-marine-style waterboxes on each shell—whether evaporator or condenser—can be switched end-for-end to obtain the desired piping arrangement.

If removal of waterboxes is necessary, refer to

“Waterbox Removal and Installation,” p. 113

.

If the waterboxes on any of the shells are exchanged end-for-end, be sure to reinstall them right-side up to

CVHH-SVX001G-EN

maintain the correct baffle arrangements. Use a new gasket with each waterbox cover.

Three-pass waterboxes have lifting lugs on the top and bottom. When reinstalling, ensure that the waterbox is oriented the same way it as removed.

Grooved Pipe Coupling

A customer-supplied, standard flexible grooved pipe coupling (Victaulic ® Style 77 or equivalent) should be used to complete the Victaulic ® connection for both

150 psig (1034.2 kPaG) and 300 psig (2068.4 kPaG) waterboxes.

When a flexible coupling such as this is installed at the waterbox connections, other flexible piping connectors

(i.e., braided-steel, elastomeric arch, etc.) are not usually required to attenuate vibration and/or prevent stress on the connections.

Table 10.

Water piping connection components

Unit

Model

CVHH

CVHH

Unit Connection

Type

Flanged (optional)

Victaulic ® (all others)

Customer Piping Connection

Victaulic ®

Customer provided

Victaulic ® coupling

Customer provided

Victaulic ® coupling

Flanged

No adapter required

Trane provided

Victaulic ® -toflange adapter

Figure 18.

Customer piping connection types

Flanged

Waterbox

Victaulic®

Waterbox

Customer

Flange Adaptor

Trane provided

Style 77 Flexible

Customer provided

• Refer to the coupling manufacturer’s guidelines for specific information concerning proper piping system design and construction methods for grooved water piping systems.

• Flexible coupling gaskets require proper lubrication before installation to provide a good seal. Refer to the coupling manufacturer’s guidelines for proper lubricant type and application.

Flange-connection Adapters

When flat-face flange connections are specified, flangeto-groove adapters are provided (Victaulic ® Style 741 for 150 psig [1034.2 kPaG] systems; Style 743 for

300 psig [2068.4 kPaG] systems). The adapters are shipped screwed to one of the chiller end-supports.

Adapter descriptions are given in the tables in

“Victaulic Gasket Installation,” p. 34

. The flange adapters provide a direct, rigid connection of flanged components to the grooved-pipe chiller waterbox connections.

Figure 19.

Typical shipping location for flange

In this case, the use of flexible type connectors (i.e., braided steel, elastomeric arch, etc.) are recommended to attenuate vibration and prevent stress at the waterbox connections. Flange adapters are not provided for CVHH CenTraVac ™ chillers with 300 psig

(2068.4 kPaG) waterboxes that have 14 in. (355.6 mm) and larger piping connections.

All flange-to-flange assembly screws must be provided by the installer. Hex head screw sizes and number required are included in the tables in

“Victaulic Gasket

Installation,” p. 34 . The four draw-bolts needed for the

14 in. (355.6 mm) and larger Style 741 (150 psig

[1034.2 kPaG]) adapters are provided. The Style 741

(150 psig [1034.2 kPaG]) flange adapter requires a smooth, hard surface for a good seal.

Connection to other type flange faces (i.e., raised, serrated, rubber, etc.) requires the use of a flange washer between the faces. Refer to the flange adapter manufacturer’s guidelines for specific information.

The Style 743 (300 psig [2068.4 kPaG]) flange adapters are designed to mate with raised-face flanges. They can be used with flat-faced flanges, but only if the raised projections on the outside face of the adapter are removed; refer to the following figure. The flangeadapter gasket must be placed with the color-coded lip on the pipe and the other lip facing the mating flange.

CVHH-SVX001G-EN 33

eq uiip eccttiiv e sse eccttiiv e sse

Figure 20.

Modifying 300 psig (2068.4 kPaG) or 21 bar flange adaptors for flat-faced flange application

Remove to mate to flat-faced flanges configuration.

3. Align and bring two pipe ends together and slide gasket into position centered between the grooves on each pipe. No portion of the gasket should extend into the groove on either pipe.

4. Open fully and place hinged Victaulic ® flange around the grooved pipe end with the circular key section locating into the groove.

5. Insert a standard hex head screw through the mating holes of the Victaulic ® flange to secure the flange firmly in the groove.

6. Tighten fasteners alternately and equally until housing screw pads are firmly together (metal-tometal); refer to

“Screw-Tightening Sequence for

Water Piping Connections,” p. 35 . Do NOT

excessively tighten fasteners.

Figure 21.

Typical Victaulic ® flange gasket configuration

Victaulic Gasket Installation

1. Inspect supplied gasket to be certain it is suited for intended service (code identifies gasket grade).

Apply a thin coat of silicone lubricant to gasket tips and outside of gasket.

2. Install gasket, placing gasket over pipe end and making sure gasket lip does not overhang pipe end.

Refer to the following figure for gasket

Table 11.

Installation data for 150 psig (1034.2 kPaG) flange adapters (Style 741)

Nominal Pipe Size in.

8 mm

200

Assembly Screw

Size (a) in.

3/4 x 3-1/2

Number of

Assembly Screws

Required

8

Screw Pattern Diameter in.

11.75

mm

298

10 250 7/8 x 4 12 14.25

362

12 300 7/8 x 4

1 x 4-1/2

12 17 432

14 350 12 18.75

476

16 400 1 x 4-1/2 16 21.25

540

18 450 1-1/8 x 4-3/4 16 22.75

578

20 500 1-1/8 x 5-1/4 20 25 635

24 600 1-1/4 x 5-3/4 20 29.5

749

(a) Screw size for conventional flange-to-flange connection. Longer screws are required when flange washer must be used.

Table 12.

Installation data for 300 psig (2068.4 kPaG) flange adapters (Style 743)

Nominal Pipe Size in.

mm

Assembly Screw

Size (a)

Number of Assembly

Screws Required in.

3/4 x 4-3/4 12

Screw Pattern Diameter in.

mm

8 219.1

13 330

10 273.0

1 x 5-1/4 16 15.25

387

12 323.9

1-1/8 x 5-3/4 16 17.75

451

(a) Screw size for conventional flange-to-flange connection. Longer screws are required when flange washer must be used.

lb

16.6

24.2

46.8

62

79

82.3

103.3

142

Weight kg

7.5

11

21.2

28.1

35.8

37.3

46.9

64.4

lb

34.3

48.3

70.5

Weight kg

15.6

21.9

32.0

34 CVHH-SVX001G-EN

Screw-Tightening Sequence for

Water Piping Connections

This section describes a screw-tightening sequence for flanges with flat gaskets or O-rings. Remember that improperly tightened flanges may leak.

flanges.

Flanges with 8 or 12 Screws

Tighten all screws to a snug tightness, following the numerical sequence for the appropriate pattern as shown in the following figure. Repeat this sequence to apply the final torque to each screw.

Figure 22.

Flange screw tightening sequence (8 or 12 screws)

1 5

7 1

12 9

4 5

8

3

3

4

7

8

2 6

8 screws

10

6 2

12 screws

11

Flanges with 16 or 20 Screws

Tighten only the first half of the total number of screws to a snug tightness, following the numerical sequence for the appropriate pattern as shown in the following figure. Next, sequentially tighten the remaining half of the screws in numerical order.

Figure 23. Flange screw tightening sequence (16 or

20 screws)

1 5

12

8

4

16

14

10

6 2

16 screws

9

15

13

3

7

11

20

1 5

9

12

16

13

17

3

8

4

18

14

10

6 2

19

20 screws

7

15

11

Pressure Testing Waterside

Piping

eq uiip h w atte piin g a wa

Waterside design pressure is either 150 psig

(1034.2 kPaG) or 300 psig (2068.4 kPaG); refer to unit nameplate or to submittal documentation.

CVHH-SVX001G-EN 35

Vent Piping

Refrigerant Vent Line

General Requirements

State and local codes, and ASHRAE Standard 15 contain requirements for venting the relief device on the chiller to the atmosphere outside of the building.

These requirements include, but are not limited to, permitted materials, sizing, and proper termination.

vent-line installation requirements based on

ASHRAE Standard 15. Most codes contain similar requirements but may vary in some significant areas. The installer must check state and local codes and follow the specific requirements applicable to the location.

Purge Discharge

To comply with ASHRAE Standard 15, the discharge piping from purge units that remove non-condensable gas from refrigerating systems must conform to the

ASHRAE Standard 15 requirements for relief piping. To help meet this requirement, the purge discharge is factory-piped to the relief device assembly.

Vent Line Materials

All materials in the relief device vent system must be compatible with the refrigerant in use. Commonly used and accepted piping materials include steel and drain/ waste/vent (DWV) copper. Consult local codes for restrictions on materials. Consult with the manufacturers of any field-provided components or materials for acceptable material compatibility.

material with R-1233zd but the glue that joins the sections of plastic pipe may not be. When considering a vent system constructed of plastic piping such as PVC, ensure that both the pipe material and the adhesive have been tested for refrigerant compatibility. In addition, verify that the local codes permit PVC for refrigerant vent lines; even though ASHRAE Standard 15 doesn’t prohibit its use, some local codes do.

The following materials for PVC pipe construction are recommended for use with R-1233zd:

Primer/Cleaner:

• Hercules—PVC Primer #60-465

• RECTORSEAL ® PVC Cleaner—Sam ™ CL-3L

Adhesives:

• Hercules—Clear PVC, Medium Body/Medium Set,

#60-020

• RECTORSEAL ® —PVC Cement, Gene ™ 404L

36

Vent Line Sizing

Vent line size must conform to local codes and requirements. In most cases, local codes are based on

ASHRAE Standard 15. ASHRAE Standard 15 provides specific requirements for the discharge piping that allows pressure-relief devices to safely vent refrigerant to the atmosphere if over-pressurization occurs. In part, the standard mandates that:

• The minimum pipe size of the vent line must equal the size of the discharge connection on the pressure-relief device. A larger vent line size may be necessary, depending on the length of the run.

• Two or more relief devices can be piped together only if the vent line is sized to handle all devices that could relieve at the same time.

• When two or more relief devices share a common vent line, the shared line must equal or exceed the sum of the outlet areas of all upstream relief devices, depending on the resulting back pressure.

ASHRAE Standard 15 provides guidance for determining the maximum vent line length. It also provides the equation and data necessary to properly size the vent line at the outlet of a pressure-relief device or fusible plug (for more information, refer to

“Vent

Line Sizing Reference,” p. 40 ).

The equation accounts for the relationship between pipe diameter, equivalent pipe length, and the pressure difference between the vent line inlet and outlet to help ensure that the vent line system provides sufficient flow capacity.

The tables in

“Vent Line Sizing Reference,” p. 40

provide additional information based on ASHRAE

Standard 15, including:

• Capacities of various vent line sizes and lengths.

However, this data applies only to conventional pressure-relief valves and NOT to balanced relief valves, rupture members (as used on Trane ® centrifugal chillers), fusible plugs, or pilot-operated valves.

• A simplified method to determine the appropriate vent-line size, using the figures (in I-P or SI units) in

“Vent Line Sizing Reference,” p. 40

. Enter the figure and down to find the maximum allowable length for that size pipe.

evaporator, standard condenser, and economizer. If the unit is equipped with any options (e.g., heat recovery, free cooling, or value(s) for those options to the total as well.

CVHH-SVX001G-EN

otte

“Vent Line Sizing

Reference,” p. 40

are applicable only for nonmanifolded vent-line runs connected to a 50 psig

(344.7 kPaG) rupture disk relief device. The pipe length provided by the table is in “equivalent feet.” The vent-line length in equivalent feet is the sum of the linear pipe length plus the equivalent length of the fittings (e.g., elbows).

Vent Line Installation

line, consult local codes for applicable guidelines and constraints.

All CenTraVac ™ centrifugal chillers are equipped with rupture disks. If refrigerant pressure within the evaporator exceeds 50 psig (344.7 kPaG), the rupture disk breaks and shell pressure is relieved as refrigerant escapes from the chiller.

A cross-section of the rupture disk assembly appears inthe following figure (rupture disk location and cross section), along with an illustration indicating the location of the rupture disk on the suction elbow.

Several general recommendations for rupture disk vent line installation are outlined as follows.

vent-line piping installation, the rupture disk must be reinstalled (as shown in the following figure [rupture disk location and cross section]).

Refer to the following procedure and contact

CenTraVac ™ Chiller Technical Service when reinstalling the rupture disk.

• Verify that the rupture disk is positioned as shown in the cross-section view that appears in the following figure (rupture disk location and cross section).

– Install the two bottom hex head screws though the pipe flanges.

– Install the rupture disk with a gasket on each side between the pipe flanges. Orient the disk with the reference arrow facing the chiller side as shown in the following figure (rupture disk location and cross section).

– Install the two top hex head screws.

– Center the disk and gaskets to the flange bore.

– Hand-tighten all screws, assuring equal pressure.

– Use a torque wrench set to 145 ft·lb (196.6 N·m) with a 24-mm socket.

– Tighten screws in a star pattern, one half turn each, to maintain even pressure on the disk.

– Final torque on all screws should be 145 ft·lb

(196.6 N·m).

• When attaching the vent line to the chiller, do NOT apply threading torque to the outside pipe of the rupture disk assembly.

da ma

• Provide support as needed for the vent line. Do

NOT use the rupture disk assembly to support the vent-line piping.

• Use a flexible connection between the vent line and the rupture disk assembly to avoid placing stress on the rupture disk. (Stress can alter rupture pressure and cause the disk to break prematurely.) The flexible connector used to isolate the rupture disk from excessive vent line vibration must be compatible with the refrigerant in use. Use a flexible, steel connector (such as the stainless-steel type MFP, style HNE, flexible pump connector from

Vibration Mounting and Control, Inc.), or equivalent. Refer to the following figure

(arrangement for rupture disk relief piping) for a recommended relief piping arrangement.

de atth

Wh en eq uiip eq uiip arre a

CVHH-SVX001G-EN 37

Figure 24. Rupture disk location and cross section of rupture disk

Outside pipe assembly

Gasket

X39003892001A application only.

• Route the vent-line piping so that it discharges outdoors in an area that will not spray refrigerant on anyone. Position the vent-line discharge at least

15 ft (4.6 m) above grade level and at least 20 ft

(6.1 m) from any building opening. Provide a ventline termination that cannot be blocked by debris or accumulate rainwater.

• Provide a drip leg on the vent line (refer to the following figure [arrangement for rupture disk relief piping]). Provide a standard 1/4-in. FL x 1/4-in. NPT, capped refrigerant service valve to facilitate liquid removal.

Cap

Bolt

Suction connection

Rupture disk eq uiip o h d tth

• Consult local regulations and codes for any additional relief line requirements.

38 CVHH-SVX001G-EN

Figure 25.

Arrangement for rupture disk relief piping

Alternate

Outside wall

Purge discharge vent line

Support this pipe

Flexible steel connection

Rupture disk

Drip leg

(length as required for easy access) assembly

1/4 in. FL x 1/4 in. NPT drain valve exhaust connection point MUST be lower than the purge height. Do NOT create a Utrap; extend to drip leg if necessary to avoid a trap.

Trane RuptureGuard

General Information

The Trane RuptureGuard ™ refrigerant containment system replaces the carbon rupture disk on new low pressure chillers utilizing R-1233zd. The

RuptureGuard ™ consists of a solid-metal, (nonfragmenting) reverse-buckling rupture disk and automatically re-seating relief valve. The relief valve and the rupture disk are rated at the chiller’s maximum working pressure level. If the chiller’s refrigerant pressure exceeds the rupture disk burst rating, the disk bursts, releasing pressure to the relief valve. The relief valve vents the pressure down to a safe level and then re-seats, thus minimizing the amount of refrigerant vented to the atmosphere. The following figure illustrates the operation of a reverse buckling rupture disk.

CVHH-SVX001G-EN

Figure 26. Reverse buckling rupture disk (top view)

Disk in normal operating position.

Chiller pressure is below 50 psig

(344.7 kPaG).

When chiller pressure exceeds the disk’s rated burst pressure, the disk begins to tear open along the score line of the outlet ring.

The disk snaps open through the score line of the outlet ring and the pressure is vented. The outlet ring is designed with a hinge area to retain the disc petal.

Flow

Flow

Flow Flow Flow

Chiller Chiller Chiller

To prevent water, refrigerant, and/or other debris such as rust from hindering the operation of the valve, a drip leg should be installed immediately after or downstream of the RuptureGuard ™ (refer to the figure in

“Connection to External Vent Line and Drip Leg,” p.

39 ).

Connection to External Vent Line and

Drip Leg

eq pm

With RuptureGuard ™ installed horizontally, the drain plug downstream of the valve relief plug and nearest to the bottom of the valve body should be piped to the drip leg in the vent line (refer to the following figure).

This will allow the removal of any condensate formed within the valve body.

Provisions, such as installing a set of flanges (refer to the following figure) or other disconnect means, must be made in the discharge vent piping. This will allow the piping downstream of the valve to be easily removed for an annual inspection, to replace the metal

RuptureGuard ™ disk, or for any other servicing need.

1. Connect the discharge of the valve assembly to the

39

vent line connected to the outdoors.

the rated flow capacity for this configuration is published in Engineering Bulletin:

RuptureGuard Selection Guide [E/CTV-EB-

10]), elbows, tees, or any other obstructions within the first 9 in. (22.86 cm) of valve discharge. Refer to ASHRAE Standard 15, national, state, and local codes for additional requirements on piping rupture disk and relief valve vent lines.

Figure 27.

External vent line and drip leg (not provided)

Purge exhaust

Rupture disk

Flange

Inlet flange

Outlet flange

Drain line

Drain valve an ™ is to be installed, it

MUST be installed properly. Failure to properly install the RuptureGuard ™ will likely result in a start-up delays and required rework and expenses that result from a failure to properly install the

RuptureGuard ™ will NOT be paid by Trane.

Vent Line Sizing Reference

Table 13. “C” values used to determine rupture disk vent line sizes (lb/min); for use with the following figure

NTON

900–1200

900–1200

900–1200

900–1200

900–1200

900–1200

Evap.

Size

(EVSZ)

100M

Cond.

Size

(CDSZ)

“C” Values for Unit Components

Total

“C”

Value

Evap. Cond. Econ.

100M 112.0

48.4

40.7

18.5

Oil

Tank

4.5

100L

130M

100L

130M

123.2

122.4

54.5

54.0

45.8

45.4

18.5

18.5

4.5

4.5

160M

200L

220L

200M

220L

220L

134.1

160.4

168.6

60.5

75.4

83.6

50.7

62.1

62.1

18.5

18.5

18.5

4.5

4.5

4.5

1500–1700

1500–1700

200L

220L

200L

220L

156.8

75.4

57.1

19.8

169.9

83.6

62.1

19.8

10HM 127.0

48.4

55.7

18.5

4.5

4.5

900–1200

900–1200

100M

130M

4.5

4.5

13HM 138.2

54.0

61.3

20HM 150.2

60.5

66.8

18.5

18.5

900–1200

1500–1700

160M

200L

4.5

4.5

20HL 174.9

75.4

75.2

19.8

1500–1700 220L 22HL 191.4

83.6

83.6

19.8

4.5

Notes:

1 .

Rupture disk diameter is 3 in.

2 .

Use the total “C” value in the following figure to determine the vent line pipe diameter.

3 .

If piping multiple rupture disks (multiple units) to a common vent line, first determine the total “C” value for each unit, and then; add all “C” values together and apply the result to the following figure.

4 .

The CVHH unit is a Simplex chiller and has (1) refrigerant circuit and (1) relief device.

40 CVHH-SVX001G-EN

Figure 28.

Rupture disk vent pipe sizing (IP units); for use with preceding table

Pipe size as a Function of “C” Value and Length of Run

1000

100

10

10 100

L = Pipe Length (Equivalent Feet)

1000 dictated by state or local code which may be different from ASHRAE Standard 15 requirements.

Pipe Size (I.D.)

Friction Factor

6 NPS

6.06 in.

f = 0.0149

5 NPS

5.05 in.

f = 0.0155

4 NPS

4.03 in.

f = 0.0163

3 NPS

3.07 in.

f = 0.0173

CVHH-SVX001G-EN 41

ASHRAE Standard 15

L =

0.214d

5

( P

2

0

– P

2

2

) fC

2

R

– d * ln(P

0

/ P

2

)

6f

• L = equivalent length of discharge piping, feet

• C r

= rated capacity as stamped on the relief device in SCFM (conversion: lb/min = SCFM * 0.0764)

C r

• f = Moody friction factor in fully turbulent flow

• d = inside diameter of pipe or tube, in.

• ln = natural logarithm

• P

2

= absolute pressure at outlet of discharge piping, psi (atmospheric pressure)

• P

0

= allowed back pressure (absolute) at the outlet of pressure relief device, psi

P

0

= (0.15

P ) + atmospheric pressure

Table 14. “C” values used to determine rupture disk vent line sizes (kg/s); for use with the following figure

NTON

900–1200

900–1200

900–1200

900–1200

900–1200

900–1200

1500–1700

Evap.

Size

(EVSZ)

100M

Cond.

Size

(CDSZ)

“C” Values for Unit Components

Total

“C”

Value

Evap. Cond. Econ.

Oil

Tank

100M 0.853 0.368 0.310 0.141 0.034

100L

130M

160M

200L

100L

130M

200M

220L

0.939 0.415 0.349 0.141 0.034

0.932 0.412 0.346 0.141 0.034

1.022 0.461 0.386 0.141 0.034

1.222 0.575 0.473 0.141 0.034

220L

200L

220L

200L

1.284 0.637 0.473 0.141 0.034

1.195 0.575 0.435 0.151 0.034

1500–1700

900–1200

220L

100M

220L 1.295 0.637 0.473 0.151 0.034

10HM 0.967

0.368 0.424 0.141 0.034

13HM 1.053 0.412 0.467 0.141 0.034

900–1200

900–1200

130M

160M 20HM 1.144 0.461 0.509 0.141 0.034

20HL 1.332 0.575 0.573 0.151 0.034

1500–1700 200L

1500–1700 220L 22HL 1.458 0.637 0.637 0.151 0.034

Notes:

1 .

Rupture disk diameter is 76.2 mm.

2 .

Use the total “C” value in the following figure to determine the vent line pipe diameter.

3 .

If piping multiple rupture disks (multiple units) to a common vent line, first determine the total “C” value for each unit, and then; add all “C” values together and apply the result to the following figure .

4 .

The CVHH unit is a Simplex chiller and has (1) refrigerant circuit and (1) relief device.

42 CVHH-SVX001G-EN

Figure 29.

Rupture disk vent pipe sizing (SI units); for use with preceding table

Pipe size as a Function of “C” Value and Length of Run

10

1

Pipe Size (I.D.)

Friction Factor

150 DN

154 mm f = 0.0149

125 DN

128 mm f = 0.0155

100 DN

102 mm f = 0.0163

1000

80 DN

78 mm f = 0.0173

0

10 100

L = Pipe Length (Equivalent Meters) dictated by state or local code which may be different from ASHRAE Standard 15 requirements.

CVHH-SVX001G-EN 43

ASHRAE Standard 15

L =

7.4381x10

–15 d

5

( P

2

0

– P

2

2

) fC

2

R

– d * ln(P

0

/ P

2

)

500f

• L = equivalent length of discharge piping, meters

• C r

= rated capacity as stamped on the relief device in SCFM (conversion: kg/s = SCFM * 0.0764 / 132.28)

C r in kg/s to lb/min for IP; lb/min = (kg/s) / 132.28)

• f = Moody friction factor in fully turbulent flow

• d = inside diameter of pipe or tube, mm

• ln = natural logarithm

• P

2

= absolute pressure at outlet of discharge piping, kPa (atmospheric pressure)

• P

0

= allowed back pressure (absolute) at the outlet of pressure relief device, kPa

P

0

= (0.15

P ) + atmospheric pressure

44 CVHH-SVX001G-EN

Insulation

Unit Insulation Requirements

Factory-installed insulation is available as an option for all units. Factory installation does NOT include insulation of the chiller feet; if required, insulation for chiller feet is provided by others. In applications where the chiller is not factory-insulated, install insulation over the areas outlined and highlighted with dashed lines as shown in the figure in

“Factory Applied

Insulation,” p. 45

.

Insulate all 1/4-in. (6.35-mm) eductor lines, one from the suction cover and one from the evaporator, to prevent sweating.

The quantities of insulation required based on unit size and insulation thickness are listed in the following table. Insulation thickness is determined at normal design conditions which are:

• Standard comfort-cooling leaving chilled water temperature

• 85°F (29.4°C) dry bulb ambient temperature

• 75 percent relative humidity

Operation outside of normal design conditions as defined in this section may require additional insulation; contact Trane for further review.

insulation around the evaporator bulbwells and ensure that the bulbwells and connections for the waterbox drains and vents are still accessible after insulation is applied. The sensor modules

(Low Level Intelligent Devices [LLIDs]) and interconnecting four-wire cable inter-processor communication (IPC) bus must be raised up above the field-installed insulation. Secure the

IPC bus to the insulation top/outer surface after insulation is completed.

wiring, or sensor modules.

Table 15. Evaporator insulation requirements

EVSZ (Standard Unit)

3/4 in. (19.05 mm) Insulation

Square Feet Square Meters

100M

100L

130M

160M

661

680

684

711

61.4

63.2

63.5

66.1

200M

200L

738

765

68.6

71.1

220M 770 71.5

220L 799 74.2

Notes:

1 .

Units are NOT insulated on the motor or refrigerant drain lines.

2 .

3/4-in. (19.05-mm) sheet insulation is installed on the evaporator, evaporator waterboxes, suction elbow, suction cover, economizer, liquid lines, and piping.

3 .

Copper oil eductor lines require pipe insulation.

Insulation Thickness

Requirements

Factory Applied Insulation

All low-temperature surfaces are covered with 3/4 in.

(19.05 mm) Armaflex ® II or equal (thermal conductivity

= 0.25 Btu/h-ft 2 [0.036 W/m 2 - K]), evaporator, waterboxes, suction elbow, economizer, and piping.

The insulation is Armaflex ® or equivalent closed cell elastomeric insulation to prevent the formation of condensation in environments with a relative humidity up to 75 percent. Chillers in high humidity areas or ice storage, low leaving water temperature (less than 36°F

[2.2°C] chilled water temperature/glycol) units, may require double thickness to prevent formation of condensation.

prre ve orrm attiio eq uiip

•• D

•• D ag e..

ag e tto xp ossu ov e tth e sse orr..

CVHH-SVX001G-EN ov e tth

45

Figure 30.

Recommended area for unit insulation

Line to eductor

Pipe (free cooling only)

Pipe

Economizer

Line from evaporator

Filter drier and eductor lines

Control panel support

Suction connection

Suction elbow

Suction cover

Eductor line

Pipe

See first two notes

Evaporator

See first note

See first two notes

• Bulbwells, drain, and vent connections must be accessible after insulating.

• All units with evaporator marine waterboxes wrap waterbox shell insulation with strapping and secure strapping with seal.

• Evaporators with pressure vessel nameplates must have insulation cut out around the nameplate. Do NOT glue insulation to the nameplate.

• Apply 2-in. (50.8-mm) wide black tape on overlap joints. Where possible apply 3-in. (7.6-cm) wide strip of

0.38-in. (9.7-mm) thick insulation over butt joint seams.

• Insulate all economizer supports.

46 CVHH-SVX001G-EN

Installation: Controls

This section covers information pertaining to the

UC800 controller hardware. For information about the

Tracer ® AdaptiView ™ display, which is used to interface with the internal chiller data and functions provided by the UC800, refer to Tracer AdaptiView

Display for Water-Cooled CenTraVac Chillers

Operations Guide (CTV-SVU01*-EN).

UC800 Specifications

Power Supply

eq uiip an mo

The UC800 (1K1) receives 24 Vac (210 mA) power from the 1T3 power supply located in the chiller control panel.

Wiring and Port Descriptions

The following figure illustrates the UC800 controller ports, LEDs, rotary switches, and wiring terminals. The numbered list following the figure corresponds to the numbered callouts in the illustration.

CVHH-SVX001G-EN 47

Figure 31.

UC800 wiring locations and connection ports

+

LINK

Front View

2 3 4 5

+ +

+ 24

VDC

MBUS

6 6

7

8

Bottom View

4. Machine bus for existing machine LLIDs (IPC3

Tracer bus).

IPC3 Bus: used for Comm 4 using TCI or LonTalk ® using LCI-C.

5. Power (210 mA at 24 Vdc) and ground terminations

(same bus as Item 4). Factory wired.

6. Not used.

7. Marquee LED power and UC800 Status indicator

(refer to the table in

“LED Description and

Operation,” p. 48 ).

8. Status LEDs for the BAS link, MBus link, and IMC link.

9. USB device Type B connection for the service tool

(Tracer ® TU).

10. The Ethernet connection can only be used with the

Tracer ® AdaptiView ™ display.

11. USB Host (not used).

Communication Interfaces

There are four connections on the UC800 that support the communication interfaces listed. Refer to the figure in

“Wiring and Port Descriptions,” p. 47

for the locations of each of these ports.

• BACnet ® MS/TP

• MODBUS ® Slave

• LonTalk ® using LCI-C (from the IPC3 bus)

• Comm 4 using TCI (from the IPC3 bus)

Rotary Switches

There are three rotary switches on the front of the

UC800 controller. Use these switches to define a threedigit address when the UC800 is installed in a BACnet ® or MODBUS ® system (e.g., 107, 127, etc.).

otte ® and

001 to 247 for MODBUS ® .

LED Description and Operation

There are ten LEDs on the front of the UC800. The following figure shows the locations of each LED and the following table describes their behavior in specific instances.

0

-

1. Rotary Switches for setting BACnet ® MAC address or MODBUS ® ID.

2. LINK for BACnet ® MS/TP, or MODBUS ® Slave (two terminals, ±). Field wired if used.

3. LINK for BACnet ® MS/TP, or MODBUS ® Slave (two terminals, ±). Field wired if used.

48 CVHH-SVX001G-EN

Figure 32.

LED locations

Marquee LED

LINK MBUS IMC

TX

RX

LINK

SERVICE

ACT

Table 16. LED behavior

LED

Marquee LED

LINK, MBUS,

IMC

Ethernet Link

Service

UC800 Status

Powered.

If the Marquee LED is green solid, the

UC800 is powered and no problems exist.

Low power or malfunction.

If the Marquee LED is red solid, the UC800 is powered but there are problems present.

Alarm.

The Marquee LED blinks red when an alarm exists.

The TX LED blinks green at the data transfer rate when the UC800 transfers data to other devices on the link.

The RX LED blinks yellow at the data transfer rate when the UC800 receives data from other devices on the link.

The LINK LED is solid green if the Ethernet link is connected and communicating.

The ACT LED blinks yellow at the data transfer rate when data flow is active on the link.

The Service LED is solid green when pressed. For qualified service technicians only. Do NOT use.

voltage (less than 30V) and high voltage circuits. Failure to do so could result in electrical noise that could distort the signals carried by the low-voltage wiring, including inter-processor communication

(IPC).

CVHH-SVX001G-EN 49

Figure 33.

Control panel: Tracer ® AdaptiView ™ main unit assembly (showing low voltage and higher voltage areas for proper routing of field wiring)

50

30 Volt Maximum 30–120 Volt Maximum

CVHH-SVX001G-EN

Installing the Tracer AdaptiView

Display

During shipment, the Tracer ® AdaptiView ™ display is boxed, shrink-wrapped, and located behind the control panel. The display must be installed at the site.

Trane, must install the Tracer ®

AdaptiView ™ display and display arm.

1. Unwrap the control panel and display arm. Locate the box containing the Tracer ® AdaptiView ™ display behind the control panel (labeled A in the following figure).

2. After the box containing the display has been removed, remove the shipping bracket from the back of the control panel (labeled B in the following figure).

3. Remove the display from the box.

and are shipped with the display.

4. Plug the power cable (labeled C in the following figure) and the Ethernet cable (labeled D in the following figure) into the bottom of the display.

from the end of the display arm.

5. Adjust the Tracer ® AdaptiView ™ display support arm so the base plate that attaches to the display is horizontal.

holes in the display support arm base plate.

8. Attach the Tracer ® AdaptiView ™ display to the display support arm base plate (labeled E in the following figure) using the M4 (metric size 4) screws referenced in Step 3.

Figure 34. Tracer ® AdaptiView ™ shipping location

A

B

Figure 35.

Power cable and Ethernet cable connections

C prriin g-prriig htt p otte

“Adjusting the Tracer AdaptiView

Display Arm,” p. 52

before attaching the display as some adjustments may be required prior to attaching the display to the support arm base.

6. Position the Tracer ® AdaptiView ™ display—with the LCD screen facing up—on top of the display support arm base plate.

will be at the top when the display is attached to the display support arm.

an ®

AdaptiView ™ display on top of the support arm base plate and do NOT drop the display.

7. Align the four holes in the display with the screw

CVHH-SVX001G-EN

D

51

Figure 36.

Display attachments to the support arm base plate

E

Adjusting the Tracer AdaptiView

Display Arm

The Tracer ® AdaptiView ™ display arm may become too loose or too tight and may need adjustment. There are three joints on the display arm that allow the display to be positioned at a variety of heights and following figure).

Figure 37.

Joint locations on the display arm

2 3

1

4

To adjust the tension on the display arm:

• At each joint in the display arm, there is either a hex screw in the proper direction to increase or decrease tension.

llo osse

• Joint 3 tension on a gas spring, which allows the Tracer ®

AdaptiView ™ display to tilt up and down.

• Joints 1 2 are covered by a plastic cap. Remove the plastic cap to access the screw. Adjust using a

13 mm wrench as necessary.

• To adjust the swivel rotation tension of the Tracer ®

AdaptiView ™ display, adjust the screw located in the support arm base plate, as described in the final step in

“Installing the Tracer AdaptiView

Display,” p. 51

.

This adjustment must be done prior to attaching the display to the support arm base.

Use a 14 mm wrench to adjust the tension.

• To adjust the left/right swivel of the entire display arm, use a 13 mm wrench to adjust the screw

52 CVHH-SVX001G-EN

Electrical Requirements

Installation Requirements

n d ea alllle d a d g dss,, y ou diin g a

• power supply wiring to the starter,

• other unit control options present, and

• any field-supplied control devices.

As you review this manual along with the wiring instructions presented in this section, keep in mind that:

• All field-installed wiring must conform to National

Electric Code (NEC) guidelines, and any applicable local, state, and national codes. For the USA, be sure to satisfy proper equipment grounding requirements per NEC.

• Compressor motor and unit electrical data

(including motor kW, voltage utilization range, rated load amps, and locked rotor amps) is listed on the chiller nameplate.

• All field-installed wiring must be checked for proper terminations, and for possible shorts or grounds.

that shipped with the chiller or the unit submittal for specific as-built electrical schematic and connection information.

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

Unit-mounted starters are available as an option on most units. While this option eliminates most fieldinstalled wiring requirements, the electrical contractor must still complete the electrical connection for the following:

CVHH-SVX001G-EN ell cco ulld da ma

Do NOT modify or cut enclosure to provide electrical access. Removable panels have been provided, and any modification should be done away from the enclosure. If the starter enclosure must be cut to provide electrical access, exercise care to prevent debris from falling inside the enclosure. Refer to installation information shipped with the starter or submittal drawings.

Electrical Requirements

Before wiring begins, observe the following electrical requirements:

• Follow all lockout/tagout procedures prior to performing installation and/or service on the unit.

• Always wear appropriate personal protective equipment.

• Wait the required time to allow the capacitor(s) to discharge; this could be up to 30 minutes.

• Verify that all capacitors are discharged prior to service using a properly rated volt meter.

• Use appropriate capacitor discharge tool when necessary.

53

• Comply with the safety practices recommended in

PROD-SVB06*-EN.

For AWG/MCM equivalents in mm

2

, refer to the following table.

Table 17.

Wire sizing reference

AWG/MCM

6

4

2 or 1

1/0

2/0

2/0 or 3/0

4/0 or 250

300

14

12

10

8

22

21

20

18

17

16

350 or 400

450 or 500

Note: AWG = American Wire Gauge mm

2

Equivalent

70

95

120

150

16

25

35

50

185

240

2.5

4

6

10

0.32

0.35

0.5

0.75

1.0

1.5

wiring in compliance with international, national, and/or local codes.

eq uiip we arr P da ncce n d ea

Wh en ne nttss,, h o lliiv e e be en h h azza viicciin g cco ott b e iin an d d viicciin g.. F de d b arrtt//rru n

54 ad diittiio ap acciitto

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

CVHH-SVX001G-EN

Trane-supplied Remote Starter Wiring

Table 18. Standard field power wiring requirements

Power Supply Wiring to Starter Panel

3-Phase Line Voltage

Starter Panel

Terminals

L1, L2, L3, and Ground (a)

Starter to Motor Power Wiring Starter

Remote Starter to Chiller Motor Junction Box

Power Supply Wiring to Unit-Mounted

Control Power Transformer

(CPTR Optional)

3-Phase Line Voltage (b)

T1 through T6

Control Power Transformer

Terminals

6Q1-1,3,5

Motor

T1 through T6

Ground

Starter to Control Panel

120 Vac Control Wiring

120 Vac Power Supply (from Starter to

Control Panel)

High Pressure Cutout to Starter

CPTR Panel GND

Starter Panel

Terminals

2X8-1, 2X8-2

2X8-G (Ground)

2X8-4

Unit Control Panel

Terminations

1X1-1, 1X1-12

1X1-G (Ground)

1X1-4

1F1 Circuit Breaker to Starter

Oil Pump Interlock

Low-voltage Starter Oil/Refrigerant Pump

Start

Mdeium-voltage Starter Oil/Refrigerant

Pump Start

Oil/Refrigerant Pump Neutral

Starter to Oil/Refrigerant Pump

Junction Box

Low Voltage 3-Phase Pump Power

2X8-3

2X8-7, 2X8-8

2X8-24

2X8-14

2X8-25

Starter Panel

Terminals

2X8-21, 2X8-22, 2X8-23

1X1-2

1X1-10, 1X1-21

1X1-21

1X1-21

1X1-16

Oil/Refrigerant

Pump Junction Box

4X4-1, 4X4-2, 4X4-3

(b)

(c)

(d)

Medium Voltage 1-Phase Pump Power 2X8-12, 2X8-13 4X4-1, 4X4-4

Low Voltage Circuits

Less Than 30 Vac

Standard Circuits

Starter Panel

Terminals

Unit Control Panel

Terminations

Inter-processor Communications (IPC)

Remote-Mounted (c) (d)

2K32-J3-3-4, or

2X1-12 to 13 if Present (Do

1T2-J53-4

Shield Ground at

NOT Ground Shield at Starter) 1X1-G (GND) Only

Notes:

1 .

All wiring to be in accordance with National Electrical Code (NEC) and any local codes.

2 .

For AWG/MCM equivalents in mm

2

, refer to the table in

“Electrical Requirements,” p. 53 .

2-wire with Gound

Comm Link

3 .

Auxiliary equipment must be powered from other sources as the chiller control panel power supplies are sized for the chiller loads only.

(a) Ground lug for a unit-mounted solid state starter or wye-delta starter is sized to accept 14 AWG solid to 8 AWG strand wire. If local codes require different lug size, it must be field-supplied and -installed.

Refer to submittal and ship-with wiring schematics for voltage requirements.

Must be separated from 120 Vac and higher wiring.

The maximum distance a Trane–supplied remote starter can be placed from the chiller is 1000 ft (305 m).

CVHH-SVX001G-EN 55

Customer-supplied Remote Starter Wiring

Table 19. Standard customer-supplied remote field wiring requirements

Power Supply Wiring to Starter Panel

Starter by Others 3-phase Power Wiring

Starter to Motor Power Wiring

Remote Starter to Chiller Motor Junction box (a)

Power Supply Wiring to Unit-Mounted Control

Power Transformer (CPTR)

3-Phase line voltage (b)

Ground

Starter to Control Panel 120 Vac Control Wiring

Power from Control Panel 1F1

Neutral from Control Panel

Ground from Control Panel

Interlock Relay Signal

Start Contactor Signal

Oil Pump Interlock

Run Contactor Signal

Transition Complete

Solid State Starter Fault (c)

Starter Panel Terminals

See Starter by Others Schematic

Starters

T1 through T6 Terminals

Control Power Transformer

Terminals

6Q1-1,3,5

CPTR Panel GND

Starter Panel Terminals

5X12-3

5X12-2

5X12-G

5X12-4

5X12-5

5X12-7, 5X12-8

5X12-10

5X12-14

5X12-12

5X12-11

Starter Panel Terminals

Motor

T1 through T6 Terminals

Unit Control Panel

Terminations

1X1-2

1X1-13

1X1-G

1K23 J10-1

1K23 J8-1

1X1-10, 1X1-21

1K23 J6-1

1K23 J12-2

1K13 J2-2

1K13 J2-1

Unit Control Panel

Terminations

Low Voltage Circuits less than 30 Vac

Standard Circuits

5X12-19 1K23 J7-1

Current Transformers (refer to table in

Sizing,” p. 57

) (Required) (d)

“Current

Transformer and Potential Transformer Wire

5X12-20

5X12-21

5X12-22

5X12-23

5X12-24

5X12-25

5X12-26

1K23 J7-2

1K23 J7-3

1K23 J7-4

1K23 J7-5

1K23 J7-6

1K23 J5-1

1K23 J5-2

Potential Transformers (Required)

5X12-27

5X12-28

1K23 J5-3

1K23 J5-4

5X12-29 1K23 J5-5

5X12-30

Notes:

1 .

All wiring to be in accordance with National Electrical Code (NC) and any local codes.

2 .

For AWG/MCM equivalents in mm

2

, refer to the table in

“Electrical Requirements,” p. 53 .

3 .

Starter by Others Specification available from your local Trane sales office.

1K23 J5-6

(a)

(b)

(c)

(d)

Wires, lugs, and fuses/breakers are sized based on National Electric Code (NEC) [NFPA 70] and UL 1995.

Refer to submittal and ship-with wiring schematics for voltage requirements.

Solid State Starter Fault input is used with low- and medium-voltage, customer-supplied solid state starters only.

Must be separated from 120 Vac and higher wiring.

Note: Phasing Must be

Maintained

56 CVHH-SVX001G-EN

Current Transformer and

Potential Transformer Wire

Sizing

For customer-supplied starter-to-chiller unit control panel starter module 1K23; these wires must be separated from 120 Vac or higher wiring.

Table 20.

Maximum recommended wire length for secondary current transformer (CT) leads in dual CT system

Wire AWG (a)

Maximum Wire Length

Secondary CT Leads

Feet Meters

8 1362.8

415.5

10

12

14

16

856.9

538.9

338.9

213.1

261.2

164.3

103.3

65.0

17 169.1

51.5

18 134.1

40.9

20 84.3

25.7

Notes:

1 .

For AWG/MCM equivalents in mm

2

, refer to the table in

“Electrical Requirements,” p. 53

.

2 .

Wire length is for copper conductors only.

3 .

Wire length is total one-way distance that the CT can be from the starter module.

(a) Wires, lugs, and fuses/breakers are sized based on National Electric

Code (NEC) [NFPA 70] and UL 1995.

Table 21. Maximum recommended total wire length for potential transformers (PTs) in a single

PT system

Wire AWG (a)

Maximum Lead Length

Feet Meters

8

10

12

14

16

5339

3357

2112

1328

835

1627

1023

643

404

254

17

18

20

21

662

525

330

262

201

160

100

79

22 207 63

Notes:

1 .

For AWG/MCM equivalents in mm

2

, refer to the table in

“Electrical Requirements,” p. 53

.

2 .

Wire length is for copper conductors only.

3 .

Wire length is maximum round trip wire length. The maximum distance the PT can be located from the starter module is half of the listed value.

(a) Wires, lugs, and fuses/breakers are sized based on National Electric

Code (NEC) [NFPA 70] and UL 1995.

Table 22.

Maximum recommended total wire length

(to and from) for PT leads in a dual PT system

Wire AWG

(a)

8

Max Wire Length

Primary

Feet Meters

3061 933

Max Wire Length

Secondary

Feet Meters

711 217

10

12

14

16

17

18

1924

1211

761

478

379

301

586

369

232

145

115

91

447

281

177

111

88

70

136

85

53

33

26

21

20

21

189

150

57

45

44

34

13

10

22 119 36 27 8

Notes:

1 .

For AWG/MCM equivalents in mm 2 , refer to the table in

“Electrical Requirements,” p. 53

.

2 .

Wire length is for copper conductors only.

3 .

Wire length is maximum round trip wire length. The maximum distance the PT can be located from the starter module is half of the listed value.

(a) Wires, lugs, and fuses/breakers are sized based on National Electric

Code (NEC) [NFPA 70] and UL 1995.

CVHH-SVX001G-EN 57

Power Supply Wiring

• Verify that the starter nameplate ratings are compatible with the power supply characteristics and with the electrical data on the unit nameplate.

n d ea alllle d a d g dss,, y ou da ma ell cco ulld diin g a

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

Three-Phase Power

Review and follow the guidelines in this section to properly install and connect the power supply wiring to the starter panel:

58 eq uiip acccce ptt o yp off

• Do NOT modify or cut enclosure to provide electrical access. Removable panels have been provided and any modification should be done away from the enclosure. If the starter enclosure must be cut to provide electrical access, exercise care to prevent debris from falling inside the enclosure.

• Use copper conductors to connect the three-phase power supply to the remote- or unit-mounted starter panel.

• Flexible conduit connections are recommended to enhance serviceability and minimize vibration transmission.

• Size the power supply wiring in accordance with

National Electric Code (NEC) and local guidelines, using the RLA value stamped on the chiller nameplate and transformer load on L1 and L2.

• Confirm that wire size is compatible with lug size stated in unit submittal.

• Make sure that the incoming power wiring is properly phased; each power supply conduit run to the starter must carry the correct number of conductors to ensure equal phase representation.

following figure) per starter diagram provided with chiller.

• When installing the power supply conduit, ensure that the position of the conduit does not interfere with the serviceability of any of the unit components, or with structural members and equipment. Ensure that the conduit is long enough to simplify any servicing that may be necessary in the future (e.g., starter).

• Electrical wire torque specifications—follow starter manufacturer’s torque specifications.

CVHH-SVX001G-EN

Figure 38.

Proper phasing for starter power supply wiring

Unit-mounted Starters

L3

L2 L1

G

L3

L2 L1

G L3

L2 L1

G

L3 L2 L1

G

L1 L2 L3

G

L3 L2 L1

G

Remote-mounted Starters

L1

L2 L3

G

L1

L2 L3

G L1

L2 L3

G

L1 L2 L3

G

Circuit Breakers and Fused

Disconnects

Any field-supplied circuit breaker or fused disconnect installed in power supplied to the chiller must be sized in compliance with National Electric Code (NEC) or local guidelines.

CE for Control Power Transformer

Option

option, chiller-mounted/UPS power, the customer needs to ensure that the supply is

NOT taken from public low voltage supplies, and that a dedicated clean source of private power supply is used for chillermounted CPTR option when a CE chiller is selected. This also includes when CPTR option is standard such as in customersupplied starters and remote-mounted medium-voltage Adaptive Frequency ™

Drives (AFDs).

All customer wiring, including power wiring to starters/ drives/CPTR Option/UPS shore power, needs to be separated: 24–27 Vdc, 110–120 Vac, and 380–600 Vac each need to be in separate conduit runs.

For 110/120 V customer wiring, including main power supply to CPTR option, it is required that the customer provides some sort of surge protection ahead of it, and all customer wiring needs to be run in conduit. Any

Ethernet cables being used by customer to interface with the Trane ® chiller must be shielded Ethernet cabling.

The customer is required to provide an overcurrent device upstream of the CPTR option in accordance with

International Electrotechnical Commission (IEC) standards and/or any applicable local and national codes.

The customer is required to follow all local, national, and/or IEC codes for installation.

Service personnel must use proper PPE for servicing and should also use proper lockout/tagout procedures during servicing. The customer should also disconnect the main supply disconnecting device upstream of the starter or drive first before performing any service on any part of the chiller, including the CPTR option, related controls, and oil pump motor circuits. In addition, service personnel should first disconnect the supply disconnecting device upstream of the CPTR option before performing any service on the CPTR option or its related circuits. Lock the CPTR option enclosure panel disconnect handle before servicing to prevent accidental pulling of the disconnect handle.

CVHH-SVX001G-EN 59

CE for Starter or Drive

• All Trane-supplied remote starters and drives used in conjunction with CVHH

Trane ® chillers will be CE-compliant per

European Union (EU) directives and

International Electrotechnical

Commission (IEC) standards to which the CVHH chillers also comply. All

Trane-supplied remote starters and drives must be used with CVHH Trane ® chillers to ensure CE compliance.

• For remote starters and drives, basic details are provided on remote starter/ drive nameplate. Please refer to the chiller unit nameplate located on the chiller-mounted control panel for details on wire sizing (minimum current ampacity) and overcurrent protection sizing upstream of the unit (maximum overcurrent protection).

• Always refer to as-built schematic wiring diagrams and the chiller

Installation, Operation, and

Maintenance manual located inside the chiller-mounted control panel

(regardless of unit- or remote-mounted starter or drive) for details on wiring, safety, installation, and warnings.

• Refer to drive-specific Installation,

Operation, and Maintenance manuals for drive and option installation specifics for unit- and remote-mounted adaptive frequency drives.

• Customers are responsible for all field wiring with respect to EMC and EMI interference. Customers are responsible to mitigate the risks associated with

EMC and EMI interference that can occur as a result of customer-provided field wiring as dictated by local, national, and international codes. This also implies that for remote-mounted starters and drives, customers are responsible for the entire field wiring into the starter/drive as well as between the starter/drive and the chiller/ compressor terminals with respect to

EMC and EMI interference. It also implies that customers are responsible for incoming power wiring to both the starter/drive and CPTR option enclosure unit-mounted panel with respect to

EMC and EMI interference.

All customer wiring, including power wiring to starters/ drives/CPTR Option/UPS shore power, needs to be separated: 24–27 Vdc, 110–120 Vac, and 380–600 Vac each need to be in separate conduit runs.

60

For 110/120V customer wiring, including power supply to CPTR option, it is required that the customer provides some sort of surge protection and all customer wiring needs to be run in conduit.

For remote starters interfacing with the Trane ® chiller, all wiring needs to be run in conduit. Any Ethernet cables being used by customer to interface with the

Trane ® chiller must be shielded Ethernet cabling.

The customer is required to provide an overcurrent protective device upstream of all starters and drives in accordance with IEC standards and/or any applicable local and national codes.

Service personnel must use proper PPE for servicing and should also use proper lockout/tagout procedures during servicing: lock the starter disconnect handle before servicing to prevent accidental pulling of disconnect handle at the starter panel. In addition, service personnel should first disconnect the main supply disconnecting device upstream of the starter or drive before performing any service on any part of the chiller.

an d m de atth d iiff n essssa

CVHH-SVX001G-EN

• Chillers with remote-mounted medium-voltage

Adaptive Frequency ™ Drives (AFDs) or customersupplied starters

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

For CE units, the convenience outlet in the control panel requires a suitable adaptor to meet the needs of customers with different plug requirements.

Control Power Transformer Option

The Control Power Transformer (CPTR) option provides a means to isolate the incoming line voltage required for the chiller control circuits and the oil/refrigerant pump from the compressor incoming line voltage. The

CPTR option provides a solution for customers that cannot afford to lose communication with the chiller or extended restart times due to lost incoming power.

The CPTR option will benefit:

• UPS customers

• Customers requiring fast restarts

• Customers who need controls sourced from a clean dedicated source

• Customers with building automation/ communication systems who want to maintain chiller status reporting during power loss

CVHH-SVX001G-EN orrtt w hiicch da ma

R o on

The standard unit-mounted CPTR option shall have an enclosure with a disconnect and will require customersupplied power.

CVHH CenTraVac ™ chillers have a low-voltage CPTR option and a medium-voltage CPTR option.

The CPTR option involves a single phase 4kVA transformer(s) and the oil pump motor circuit to be located together in an enclosure that is unit-mounted.

There is three-phase line power between 380 to

600 Vac feeding this enclosure. Wherever the 4kVA transformer is located, the oil pump motor circuit will be located along with it.

With the CPTR option, the control power transformer(s) and oil pump motor circuit are NOT inside of the starter.

For the low-voltage CPTR option, the single phase

4kVA transformer feeds the 120V control power to all of the controls. The three-phase line power feeds a motor starter and overload oil pump motor circuit which feeds the three-phase oil pump motor.

For the medium-voltage CPTR option, there are two single-phase 4-kVA transformers: one of the 4kVA transformers feeds the 120V control power to all of the controls. The second transformer feeds a combination motor controller oil pump motor circuit which then feeds a single-phase oil pump motor.

overcurrent protection and minimum current ampacity values for connecting to the CPTR option enclosure.

Service personnel are required to ensure that the incoming power supply voltage provided by the customer to the CPTR option enclosure unit-mounted panel is as per submittal and nameplate.

Power Factor Correction

Capacitors (Optional)

Power factor correction capacitors (PFCCs) are designed to provide power factor correction for the compressor motor. PFCCs are available as an option for unit- and remote-mounted starters.

61

an d rre an d ssu

• Verify PFCC voltage rating is greater than or equal to the compressor voltage rating stamped on the unit nameplate.

• Refer to the wiring diagrams that shipped with the unit for specific PFCC wiring information.

ap plliicca ue nttlly usse ap orrss

Figure 39. Option 1—PFCCs installed downstream of starter contactor, upstream of current transformers

Motor Starter

Contactor

Current

Transformer

Power

Circuit

1

2

3

Motor

Fused

Disconnect or Suitable

Breaker

Enclosed

3-phase

Capacitor

Unit

Fuses

Diisscco nn ne nttss p de d b d p err N A 7 0E ad diittiio ap acciitto arrtt//rru n otth errss,, rre

X39003892001A

PF CC application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

an d

62 CVHH-SVX001G-EN

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

Simultaneously disconnect capacitors and load from line power. If the capacitors are not switched offline when the load is disconnected, they continue to add capacitance to the electrical distribution system. A leading power factor—too much capacitance—may eventually develop. This overprotection causes poor voltage regulation (i.e., voltage is high when the circuit is unloaded, then drops as loads are added).

Figure 40. Option 2—PFCC wires routed through current transformers

Fused

Disconnect or Suitable

Breaker

Current

Transformer

1

Power

Circuit

2 Motor

3

Motor Starter

Contactor

Fuses

Enclosed

3-phase

Capacitor

Unit

Size motor overload protection to account for capacitor-supplied current. Overloads are typically set to measure the total current drawn by the motor. When

PFCCs are used, they become the source of part of that current. If the current they provide is not registered by the overload protectors, potentially damaging amperage can reach the motor. The simplest way to ensure that the overloads detect all current supplied to the motor is to position the PFCCs upstream of the current transformers as shown in the preceding figure

(Option 1). If the capacitor connection points are downstream of the current transformers, route the

PFCC leads through the current transformers as shown in the preceding figure (Option 2). This ensures that the overloads register both line and capacitor-supplied current.

Interconnecting Wiring

Typical equipment room conduit layouts with and without unit-mounted starters are shown in the following two figures.

starter panel, compressor, and control panel is factory-installed with unit-mounted starters. However, when a remote-mounted starter is used, the interconnecting wiring must be field-installed.

incoming wiring to the starter.

CVHH-SVX001G-EN 63

Figure 41.

Typical equipment room layout for units with unit-mounted starters

1

2

3

Figure 42. Typical equipment room layout for units with remote-mounted starters

1

2 4

7

5

6

3

1. Line side power conduits

2. Unit-mounted starter

3. Unit control panel

64

1. Line side power conduits

2. Remote-mounted starter

3. Unit control panel

4. Inter-processor communication (IPC) circuit conduit less than 30V (and current transformer/potential transformer [CT/PT] wiring for starters by others) unit control panel (1000 feet [304.8 m] maximum).

5. Motor terminal box

6. 115V control conduit of the until control panel.

7. Lead power wiring approximate unit control panel knock out locations. To prevent damage to the unit control panel components, do NOT route control conduit into the top of the box.

Starter to Motor Wiring

(Remote-Mounted Starters Only)

Ground Wire Terminal Lugs

Ground wire lugs are provided in the motor terminal box and in the starter panel.

CVHH-SVX001G-EN

Terminal Clamps

eq uiip acccce ptt o yp off

Wire Terminal Lugs

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

Terminal clamps are supplied with the motor terminals to accommodate either bus bars or standard motor terminal wire lugs. Terminal clamps provide additional surface area to minimize the possibility of improper electrical connections.

an d//o

Wire terminal lugs must be field supplied.

• Use field-provided, crimp-type wire terminal lugs properly sized for the application.

side lugs are listed on the starter submittal drawings supplied by the starter manufacturer or Trane. Carefully review the submitted wire lug sizes for compatibility with the conductor sizes specified by the electrical engineer or contractor.

• On 600V and below, a terminal clamp with a

3/8-in. (9.525-mm) bolt is provided on each motor terminal stud; use the factory-supplied Belleville washers on the wire lug connections. The following figure illustrates the junction between a motor terminal stud and terminal lug.

• Torque for this assembly is 24 ft·lb (32.5 N·m).

• Install but do NOT connect the power leads between the starter and compressor motor. (These connections will be completed under supervision of a qualified Trane service engineer after the pre-start inspection.)

CVHH-SVX001G-EN 65

Figure 43.

Terminal stud, clamp, and lug assembly

(600V and below)

2 diagram (showing the electrical connections required between the remote-mounted starter and the control panel).

(30 volts) section of the control panel.

When sizing and installing the electrical conductors for these circuits, follow the guidelines listed. Use 14 AWG for 120V control circuits unless otherwise specified. For

AWG/MCM equivalents in mm 2 , refer to the table in

“Electrical Requirements,” p. 53

.

1

4

5

1. Belleville washer

2. Terminal lugs

3. Terminal clamp

4. Motor terminal stud

5. Terminal mounting bolt

3

Bus Bars

orrtt w hiicch da ma e..

de brriiss ffrro R o pttiio

Bus bars and extra nuts are available as a Trane option.

Install the bus bars between the motor terminals when using a starter that is:

• A low-voltage Adaptive Frequency ™ Drive (AFD)

• Across-the-line

• Primary reactor/resistor

• Autotransformer

• Customer-supplied

Connect T1 to T6, T2 to T4, and T3 to T5.

high-voltage applications since only three terminals are used in the motor and starter.

Starter to Control Panel Wiring

The unit submittal includes the field wiring connection diagram and the starter-to-control-panel connection

66 ell cco ulld da ma voltage (less than 30V) and high-voltage circuits. Failure to do so could result in electrical noise that may distort the signals carried by the low-voltage wiring, including the inter-processor communication (IPC) wiring.

To wire the starter to the control panel, use these guidelines:

• If the starter enclosure must be cut to provide electrical access, exercise care to prevent debris from falling inside the enclosure. Do NOT cut the

Adaptive Frequency ™ Drive (AFD) enclosure.

• Use only shielded, twisted-pair wiring for the interprocesssor communication (IPC) circuit between the starter and the control panel on remotemounted starters.

18 AWG for runs up to 1000 ft (304.8 m). For

AWG/MCM equivalents in mm 2 , refer to the table in

“Electrical Requirements,” p. 53 . The

polarity of the IPC wiring is critical for proper operation.

• Separate low-voltage (less than 30V; refer to the table in

“Trane-supplied Remote Starter Wiring,” p.

55

) wiring from the 115V wiring by running each in its own conduit.

• When routing the IPC circuit out of the starter enclosure, ensure that it is at least 6 in. (16 cm) from all wires carrying a higher voltage.

CVHH-SVX001G-EN

diin g a n d ea alllle d a d g dss,, y ou

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

• The IPC wiring shield should be grounded on one end only at control panel end. The other end should be unterminated and taped back on the cable sheath to prevent any contact between shield and ground.

• Oil Pump Interlock: All starters must provide an interlock (normally open) contact with the chiller oil pump connected to the control panel at terminals 1X1-10 and 1X1-21 (14 AWG; for AWG/MCM equivalents in mm

2

, refer to the table in

“Electrical

Requirements,” p. 53 ). The purpose of

this interlock is to maintain the oil pump signal in the event that a starter failure, such as welded contacts, keeps the chiller motor running after the controller interrupts the run signal.

application only.

X39003892001A

CVHH-SVX001G-EN 67

Medium Voltage Motor

n d ea na ve viicciin g.. F

The motor is suitable for remote-mounted across-theline (including circuit breaker starting), primary reactor, autotransformer, or solid-state starting. Refer to the unit nameplate for motor data including RLA, LRA, etc.

In all cases of non-Trane supplied starters, the Trane

Engineering Specification for UC800 Starter By Others

(available through your local Trane office) must be followed in order to ensure proper function and protection of the chiller. A disconnecting means and short-circuit protection must be installed ahead of the starter, unless they are included as part of the starter.

documentation, construction, compatibility, installation, start-up, or long term support of starters provided by others.

Motor Terminal Box

A large steel motor terminal box is provided to allow for the field connection of the motor power supply wire to the motor. There are three sizes available depending on voltage and motor frame size.

Figure 44.

Motor terminal box dimensions, in. (mm)

A

48

(1219)

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

All electrical circuits shall be treated as energized until all lockout/tagout procedures are in place and the circuit has been tested to verify that it is de-energized.

The medium-voltage motor terminal box cover must

NOT be removed if power is present, or if there is a possibility that power may be present. Working on energized medium-voltage circuits is not an approved practice for normal HVAC maintenance or service.

68

25

(635)

37.4

(949)

B

C

35

(889)

18

(457)

26.5

(674)

29

(737)

8

(203)

26.4

(670)

CVHH-SVX001G-EN

Table 23. Motor terminal box dimensions

Box Weight kg

Volt Range lb

A

B

C

564 (a)

259

129

256

(a)

117.3

58.5

6000–13.8kV

Frame 6800, 6800L

2300–13.8kV

Frame 440E, 5000, 5800, 580L

380–600 Vac

Frame 440E, 5000

Note: Lifting holes are 0.56 in. (14.3 mm).

(a) Motor terminal box cover-only weight is 55 lb (24.9 kg).

the motor terminals MUST be protected against impact or stress damage. Field fabrication of a cover or guard is required.

• The motor terminal box is large enough to accommodate the use of stress cones.

• If conduit is applied, a flexible connection of the conduit to the box should be made to allow for unit serviceability and for vibration isolation. The cable should be supported or protected against abrasion and wear on any edges or surfaces. Cable or conduit openings can be cut at any location in the box sides, top, or bottom for cable entry. Always ensure that NO debris remains in the box after cutting cable entry holes.

Motor Supply Wiring

diin g a

CVHH-SVX001G-EN n d ea alllle d a d g dss,, y ou

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

Motor circuit wire sizing by the installer must be made in accordance with the National Electric Code (NEC) or any other applicable codes.

Three terminals are provided on the chiller for the connection of power to the motor from the starter.

Power leads to motors must be in multiples of three, with equal phase representation in all conduits or wire trays. To limit the effects of corona or ionization with cables carrying more than 2000V, Trane requires that the power cable have a metallic shield, unless the cable is specifically listed or approved for non-shielded use.

If the cable is shielded, the shielding must be grounded at one end (grounding is typically done at the starter or supply end).

Care must be taken while routing the incoming cables to ensure that cable loads or tensions are not applied to the terminal or premature terminal failure could result.

Motor Terminals

Field-provided, ring-type lugs, with no sharp edges or corners, must be used by a qualified installer to connect the power wiring to the motor terminals.

69

Follow all instructions provided with the field-provided lugs to ensure proper connections.

recommended to reduce and control longitudinal and radial electrical stresses at the cable ends.

Prior to assembly the terminal stud, nuts, and lug should be inspected and cleaned to ensure they are not damaged or contaminated. When attaching starter leads to 2.3 to 6.6 kV motor terminals, the M14x2 brass jam nuts should be tightened to a maximum torque of

24 to 30 ft·lb (32.5 to 40.7 N·m). Always use a second wrench to backup the assembly and prevent applying excessive torque to the terminal shaft.

(see compressor model number for motor frame) use the same motor terminals as the 10 to

13.8kV motors.

The motor terminal on a 10 to 13.8kV motor has a copper shaft that is threaded M14 x 2-6 G. Brass nuts are provided on the motor terminals to retain the lugs, and the final connection should be tightened to 24 to

30 ft·lb (32.5 to 40.7 N·m).

CE for Medium Voltage Starter

Diisscco nn arrtt//rru n ne nttss p de d b d p err N A 7 0E ad diittiio ap orrss,, sse otth errss,, rre e m otto uiip me asssse mb y--o nlly

Before beginning wiring and torquing, ensure proper motor terminal care and do NOT apply any excess stress.

Ground Wire Terminal Lug

A ground wire lug is provided in the motor terminal box to allow the field connection of an earth ground.

The lug will accept a field-supplied ground wire of #8 to

#2 AWG. For AWG/MCM equivalents in mm 2 , refer to the table in

“Electrical Requirements,” p. 53 . After

completing the field connection of wiring, inspect and clean the motor terminals and motor housing, and remove any debris before reinstalling the motor terminal box cover. The cover must be re-installed onto the motor terminal box and all bolts installed. Do NOT operate the chiller with the motor terminal box cover removed or with any loose or missing cover bolts.

application only.

X39003893001A

70 CVHH-SVX001G-EN

• Before servicing, disconnect all power sources and allow at least 10 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

• Customers are responsible for all field wiring in compliance with local, national, and/or international codes.

• Any fuses inside the medium-voltage starter enclosure may be energized.

• Power factor correction capacitors

(PFCC) fuses must be installed before energizing the medium-voltage starter.

• Do NOT modify or disassemble the medium-voltage starter.

• Use only factory-authorized replacement parts.

• Do NOT install or energize the mediumvoltage starter if it has been damaged.

• Contactor must be bolted in place after installation; maximum torque is 14 ft·lb

(19.0 N·m).

application only.

combustible surface could result in a fire.

To minimize the risk of possible fires, a floor plate of at least 0.056 in. (1.43 mm) thick galvanized or 0.63 in. (1.6 mm) thick uncoated steel extending at least 5.9 in.

(150 mm) beyond the equipment on all four sides must be used.

CVHH-SVX001G-EN 71

System Control Circuit Wiring (Field Wiring)

Table 24. Unit control panel wiring 120 Vac

Standard Control Circuits: Unit

Control Panel Control Wiring

(120 Vac)

Chilled Water Flow Proving Input (a)

Condenser Water Flow Proving

Input (b)

Chilled Water Pump Relay Output

Condenser Water Pump Relay

Output

Optional Control Circuits (120

Vac)

Alarm Relay MAR (Non-Latching)

Output

Limit Warning Relay Output 1K19-J2-4 to 6

Alarm Relay MMR (Latching) Output 1K19-J2-7 to 9

Compressor Running Relay Output 1K19-J2-10 to 12

Maximum Capacity Relay Output 1K20-J2-1 to 3

Head Relief Request Relay Output 1K20-J2-4 to 6

Purge Alarm Relay Output

Ice Making Relay Output

1K20-J2-7 to 9

1K15-J2-10 to 12

Free Cooling Relay Output

Standard Low Voltage Circuits

(Less than 30 Vac) (c)

1K21-J2-4 to 6

Unit Control Panel Terminations

External Auto Stop Input 1K2-J2-1 to 2

Emergency Stop Input

Unit Control Terminations

1X1-5 to 1K16-J3-2

1X1-6 to 1K16-J2-2

Note:

1K15-J2-4 to 6

1K15-J2-1 to 3

Input or Output Type

Binary Input

Binary Input

Binary Output

Binary Output

Defaults are factory programmed; alternates can be selected at start-up using the service tool.

1K19-J2-1 to 3

1K2-J2-3 to 4

Binary Output

Binary Output

Binary Output

Binary Output

Binary Output

Binary Output

Binary Output

Binary Output

Binary Output

Input or Output Type

Binary Input

Binary Input

Contacts

Normally Open, Closure with Flow

Normally Open, Closure with Flow

Normally Open

Normally Open

Normally Open

Normally Open

Normally Open

Normally Open

Normally Open

Normally Open

Normally Open

Normally Open

Normally Open

Contacts

Closure Required for Normal

Operation

Closure Required for Normal

Operation

Optional Low Voltage Circuits

External Base Loading Enable Input

External Hot Water Control Enable

Input

External Ice Machine Control

Enable Input

External Free Cooling Input Enable

Input

% RLA Compressor Output

External Condenser Pressure

Output

Evaporator/Condenser Differential

Pressure Output

1K8-J2-1 to 2

1K8-J2-3 to 4

1K9-J2-1 to 2

1K10-J2-1 to 2

1K5-J2-1 to 3

1K5-J2-4 to 6

1K5-J2-4 to 6

Binary Input

Binary Input

Binary Input

Binary Input

Analog Output

Analog Output

Analog Output

Condenser Head Pressure Control

External Current Limit Setpoint

Input

External Chilled Water Setpoint

Input

External Base Loading Setpoint

Input

1K5-J2-4 to 6

1K6-J2-2 to 3

1K6-J2-5 to 6

1K7-J2-2 to 3

Analog Output

Analog Input

Analog Input

Analog Input

Generic Refrigerant Monitor Input 1K7-J2-5 to 6 Analog Input

Outdoor Air Temperature Sensor

Tracer ® Comm 4 Interface

Inter-processor Communication

(IPC) Bus Connection and Sensor

1K3-J2-1(+) to 2(-)

1K3-J2-3(+) to 4(-)

Communication and Sensor

Communication to Tracer ®

BACnet ® or MODBUS ® 1K1, 5(+) to 6(-)

Communication to BACnet ® or

MODBUS ®

LonTalk ® Comm 5 Interface

1K4-J2-1(+) to 2(-)

1K4-J2-3(+) to 4(-) Communication to LonTalk ®

Left Panel

Note: All wiring to be in accordance with National Electrical Code (NEC) and any local codes.

Normally Open

Normally Open

Normally Open

Normally Open

2–10 Vdc

2–10 Vdc

2–10 Vdc

2–10 Vdc

2–10 Vdc, or 4–20 mA

2–10 Vdc, or 4–20 mA

2–10 Vdc, or 4–20 mA

2–10 Vdc, or 4–20 mA

(As Ordered; See Sales Order)

(As Ordered; See Sales Order)

(As Ordered; See Sales Order)

(a) If the Chilled Water Flow Proving Input is a factory-installed ifm efector ® flow-sensing device, the secondary field device (recommended with 38°F [3.3°C] and lower leaving chilled water temperatures) for proof of flow connects from 1X1-5 to 1K26-4 (binary input; normally open, closure with flow). Remove factory jumper when used.

72 CVHH-SVX001G-EN

Table 24. Unit control panel wiring 120 Vac (continued)

(b)

(c)

If the Condenser Water Flow Proving Input is a factory-installed ifm efector ® flow-sensing device, the secondary (optional) field device for proof of flow connects from 1X1-6 to 1K27-4 (binary input; normally open, closure with flow). Remove factory jumper when used.

Standard low-voltage circuits (less than 30 Vac) must be separated from 120 Vac or higher wiring.

Water Pump Interlock Circuits and Flow Switch Input

n d ea na dv application only.

viicciin g.. F

X39003892001A

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

and the condenser water proof of flow do NOT require external power. Refer to the wiring diagrams that shipped with the chiller.

Chilled Water Pump

1. Wire the evaporator water pump contactor (5K42) to a separate 120 volt single-phase power supply with 14 AWG, 600V copper wire. For AWG/MCM equivalents in mm

2

, refer to the table in

“Electrical

Requirements,” p. 53

.

2. Connect circuit to 1K15-J2-6.

3. Use 1K15-J2-4 120 Vac output to allow the control panel to control the evaporator water pump, or wire the 5K1 contactor to operate remotely and independently of the control panel.

Chilled Water Proof of Flow

When this circuit is installed properly and the evaporator pump is running and providing the required minimum flow, this circuit will prove the evaporator water flow for the chiller controls. Proof of evaporator water flow is required before the start sequence will be allowed to proceed and a loss of evaporator water flow during chiller operation will result in a chiller shutdown.

Refer to as-built schematics on the inside of the control panel for field wiring. This is a dry binary input; normally-open, closure for flow. Apply no external power.

1. With factory-installed ifm efector ® flow-sensing devices, a field-provided secondary flow-sensing device is recommended with applications having

38°F (3.3°C) and below leaving evaporator water temperatures. When a secondary flow-sensing device is used, remove the factory jumper and install its contacts between 1X1-5 to 1K26-4; this places the secondary flow sensing device in series with the ifm efector ® flow-sensing device.

2. For field-provided primary proof of flow devices, connect the primary proof of flow device between terminals 1X1-5 to 1K16-J3-2. A secondary field device is recommended with applications having

38°F (3.3°C) and below leaving evaporator water temperatures, and must be field-wired in series with the primary proof of flow device.

Condenser Water Pump

1. Wire the condenser water pump contactor (5K43) to a separate 120-volt, single-phase power supply with

14 AWG, 600-volt copper wire. For AWG/MCM equivalents in mm

2

, refer to the table in

“Electrical

Requirements,” p. 53

.

2. Connect circuit to control panel terminals 1K15-J2-

3.

3. Use 1K15-J2-1 120 Vac output to allow the control

CVHH-SVX001G-EN 73

panel to control the condenser pump.

Condenser Water Proof of Flow

When this circuit is installed properly and the condenser pump is running and providing the required minimum condenser water flow, this circuit will prove the condenser water flow for the chiller controls. Proof of condenser water flow is also required for the start sequence will be allowed to proceed and a loss of condenser water flow during chiller operation will result in a chiller shut-down.

Refer to as-built schematics on the inside of the control panel for field wiring. This is a dry binary input; normally-open, closure for flow. Apply no external power.

1. With factory-installed ifm efector ® flow-sensing devices, a secondary field-provided flow-sensing device is optional. When a secondary flow-sensing device is used, remove the factory jumper, and install its contacts between 1X1-5 to 1K27-4; this places the secondary flow sensing device in series with the ifm efector ® flow-sensing device.

2. For field-provided primary proof of flow devices, connect the primary proof of flow device between terminals 1X1-6 to 1K16-J2-2. The secondary field provided flow sensing device is optional; however, when it is present, it must be field-wired in series with the primary proof of flow device.

Sensor Circuits

All sensors are factory-installed except the optional outdoor air temperature sensor (refer to the following figure for sensor locations). This sensor is required for the outdoor air temperature type of chilled water reset.

Use the following guidelines to locate and mount the outdoor air temperature sensor. Mount the sensor probe where needed; however, mount the sensor module in the control panel.

74 CVHH-SVX001G-EN

Figure 45.

CVHH sensor locations

234

See Detail A

]\a

=q ty ty er er

=q p [ u

See Detail B

9

78

1 ty ty o er er

0

1. Tracer ® AdaptiView ™ display module

2. Motor winding temperature 1

3. Motor winding temperature 2

4. Motor winding temperature 3

5. Oil pump discharge pressure transducer

6. Oil tank pressure transducer

7. Evaporator water differential pressure transducer

8. Condenser water differential pressure transducer

9. Compressor discharge refrigerant temperature sensor

10. Evaporator saturated refrigerant temperature sensor

11. Condenser saturated refrigerant temperature sensor

12. Second condenser entering water temperature sensor (used on HTRC)

13. Second condenser leaving water temperature sensor (used on HTRC)

14. Oil tank temperature sensor

15. Evaporator entering water temperature sensor

16. Evaporator leaving water temperature sensor

17. Condenser entering water temperature sensor

18. Condenser leaving water temperature sensor

19. Inboard bearing temperature sensor

20. Outboard bearing temperature sensor w 6 f

CVHH-SVX001G-EN

Detail A Detail B sd

5 i

-

75

21. Oil cooling solenoid valve

22. Inlet guide vane first stage actuator

23. Inlet guide vane second stage actuator

24. Outboard bearing pad temperature sensor 1

25. Outboard bearing pad temperature sensor 2

26. Outboard bearing pad temperature sensor 3

27. Condenser high pressure cut out switch

28. Condenser refrigerant pressure transducer

29. Oil tank vent line valve

CWR—Outdoor Option

The outdoor temperature sensor is similar to the unitmounted temperature sensors in that it consists of the sensor probe and the module. A four-wire interprocessor communication (IPC) bus is connected to the module for 24 Vdc power and the communications link.

Trane recommends mounting the sensor module within the control panel and the sensor two wire leads be extended and routed to the outdoor temperature sensor probe sensing location. This ensures the fourwire inter-processor control (IPC) bus protection and provides access to the module for configuration at start-up.

The sensor probe lead wire between the sensor probe and the module can be separated by cutting the twowire probe lead leaving equal lengths of wire on each device: the sensor probe and the sensor module.

remain together or inaccuracy may occur.

These wires can then be spliced with two 14 to 18 AWG

600V wires of sufficient length to reach the desired outdoor location with a maximum length 1000 ft

(304.8 m). For AWG/MCM equivalents in mm 2 , refer to the table in

“Electrical Requirements,” p. 53 . The

module four-wire bus must be connected to the control panel four-wire bus using the Trane-approved connectors provided.

The sensor will be configured (given its identity and become functional) at start-up when the Trane service technician performs the start-up configuration. It will

NOT be operational until that time.

leads, be sure to cover the shield wire with tape at the junction box and ground it at the control panel. If the added length is run in conduit, do

NOT run them in the same conduit with other circuits carrying 30 or more volts.

low-voltage (less than 30V) and high voltage circuits. Failure to do so could result in electrical noise that may distort the signals carried by the low-voltage wiring, including the IPC.

76

Optional Control and Output Circuits

Install various optional wiring as required by the owner’s specifications (refer to

“System Control Circuit

Wiring (Field Wiring),” p. 72

).

Optional Tracer Communication

Interface

This control option allows the control panel to exchange information—such as chiller status and operating set points—with a Tracer ® system.

prevent electrical noise interference.

Additional information about the Tracer ® communication interface option is published in the

Installation and Operation manual that ships with the

Tracer ® communication interface

Starter Module Configuration

The starter module configuration settings will be checked (and configured for remote starters) during start-up commissioning.

starter checks, it is recommended that the line voltage three-phase power be turned off and secured (locked out), and then that a separate source control power (115 Vac) be utilized to power up the control circuits.

Use the as-built starter schematic to ensure correct fuse and terminals. Verify that the correct fuse is removed and that the control circuit connections are correct; then apply the 115 Vac separate source power to service the controls.

Schematic Wiring Drawings

Please refer to the submittals and drawings that shipped with the unit. Additional wiring drawings for

CenTraVac ™ chillers are available from your local

Trane office.

CVHH-SVX001G-EN

Operating Principles

General Requirements

Operation and maintenance information for CVHH

CenTraVac ™ chillers are covered in this section. This includes both 50 and 60 Hz centrifugal chillers equipped with the Tracer ® AdaptiView ™ UC800 control system. This information pertains to all chiller types unless differences exist, in which case the sections are listed by chiller type as applicable and described separately. By carefully reviewing this information and following the instructions given, the owner or operator can successfully operate and maintain a CenTraVac ™ chiller. If mechanical problems do occur, however, contact a Trane service technician to ensure proper diagnosis and repair of the unit.

an ™ chillers can operate through surge, it is NOT recommended to operate them through repeated surges over long durations. If repeated surges of long durations occur, contact your Trane Service

Agency to resolve the issue.

Cooling Cycle

When in the cooling mode, liquid refrigerant is distributed along the length of the evaporator and sprayed through small holes in a distributor (i.e., running the entire length of the shell) to uniformly coat each evaporator tube. Here, the liquid refrigerant absorbs enough heat from the system water circulating through the evaporator tubes to vaporize. The gaseous refrigerant is then drawn through the eliminators

(which remove droplets of liquid refrigerant from the gas) and the first-stage variable inlet guide vanes, and into the first-stage impeller.

CVHH 3-Stage Compressor

Compressed gas from the first-stage impeller flows through the fixed, second-stage inlet vanes and into the second-stage impeller. Here, the refrigerant gas is again compressed, and then discharged through the third-stage variable guide vanes and into the thirdstage impeller. After the gas is compressed a third time, it is discharged into the condenser. Baffles within the condenser shell distribute the compressed refrigerant gas evenly across the condenser tube bundle. Cooling tower water circulated through the condenser tubes absorbs heat from the refrigerant, causing it to condense. The liquid refrigerant then passes through an orifice plate and into the economizer.

The economizer reduces the energy requirements of the refrigerant cycle by eliminating the need to pass all gaseous refrigerant through three stages of compression (refer to the following figure). Notice that some of the liquid refrigerant flashes to a gas because of the pressure drop created by the orifice plates, thus

CVHH-SVX001G-EN further cooling the liquid refrigerant. This flash gas is then drawn directly from the first and second stages of the economizer into the third- and second-stage impellers of the compressor, respectively. All remaining liquid refrigerant flows through another orifice plate to the evaporator.

Figure 46.

Pressure enthalpy curve, 3-stage

P

4

P

3

P

2

P

1

8

1

7

6

Condenser

High Side Economizer

Low Side Economizer

Evaporator

5

Compressor

Third Stage

4

Compressor

Second Stage

3

Compressor

First Stage

2

Enthalpy

Figure 47.

Refrigerant flow, 3-stage

CVHH 2-Stage Compressor

Compressed gas from the first-stage impeller is discharged through the fixed, second-stage variable guide vanes and into the second-stage impeller. Here, the refrigerant gas is again compressed, and then discharged into the condenser. Baffles within the condenser shell distribute the compressed refrigerant gas evenly across the condenser tube bundle. Cooling tower water circulated through the condenser tubes absorbs heat from the refrigerant, causing it to condense. The liquid refrigerant then passes through an orifice plate and into the economizer.

The economizer reduces the energy requirements of the refrigerant cycle by eliminating the need to pass all gaseous refrigerant through both stages of

77

compression (refer to the following figure). Notice that some of the liquid refrigerant flashes to a gas because of the pressure drop created by the orifice plate, thus further cooling the liquid refrigerant. This flash gas is then drawn directly from the economizer into the second-stage impellers of the compressor. All remaining liquid refrigerant flows out of the economizer, passing through another orifice plate and into the evaporator.

Figure 48.

Pressure enthalpy curve

Oil and Refrigerant Pump

Compressor Lubrication System

A schematic diagram of the compressor lubrication system is illustrated in the following figure. Oil is pumped from the oil tank (by a pump and motor located within the tank) through an oil pressure regulating valve designed to maintain a net oil pressure of 20 to 24 psid (137.9 to 165.5 kPaD). It is then filtered and sent to the braze plate heat exchanger oil cooler located above the oil tank and on to the compressor motor bearings. From the bearings, the oil drains back to the oil tank.

P

3

P

2

6

P

1

1

5

Condenser

Economizer

Evaporator

2

4

Compressor

Second Stage

3

Compressor

First Stage

Enthalpy

Figure 49.

Refrigerant flow, 2-stage

78 CVHH-SVX001G-EN

Figure 50.

Oil refrigerant pump

1 w

Compressor lubrication system

Motor cooling system

Oil reclaim system q

= e

5

6 u

4

-

8 i o p 7 t r

2 3 0 9

1. Motor coolant return to condenser, 2.125 in. (53.975 mm) OD

2. Oil tank vent line, 2.125 in. (53.975 mm) OD

3. Vent line actuated ball valve

4. Condenser

5. High pressure condenser gas to drive oil reclaim eductors, 0.375 in. (9.525 mm) OD

6. Oil return to tank

7. Oil tank

8. Oil cooler braze plate heat exchanger

9. Oil reclaim from evaporator (second eductor), 0.25 in. (6.35 mm) OD

10. Liquid refrigerant to pump, 1.625 in. (41.275 mm) OD

11. Economizer

12. Oil supply to bearings, 0.875 in. (22.225 mm) OD

13. Purge

14. Compressor

15. Liquid refrigerant motor coolant supply, 1.125 in. (28.575 mm) OD

16. Liquid refrigerant to economizer

17. Liquid refrigerant to evaporator

18. Evaporator

19. Oil reclaim from suction cover (first eductor), 0.25 in. (6.35 mm) OD

20. Motor coolant filter

21. Oil tank junction box enclosure

22. Oil pump motor terminal box y

CVHH-SVX001G-EN 79

viicciin g.. IIff sse allll P errsso pa ne de atth de viicce

VH H a

80 an d//o au xiilliia n b x ed urre ag utt

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

To ensure proper lubrication and prevent refrigerant from condensing in the oil tank, two 750-watt heaters are in wells in the oil tank and are used to heat the oil while the unit is off. With the default settings, the oil heaters are de-energized when the unit starts. The heaters energize as needed to maintain 128°F to 133°F

(53.3°C to 56.1°C) when the chiller is not running.

When the chiller is operating, the temperature of the oil tank is typically 100°F to 140°F (37.8°C to 60.0°C). The oil return lines are routed into a separation chamber in the oil tank. Gas flow exits out the top of the oil tank and is vented to the evaporator.

A dual eductor system, using high pressure condenser gas, reclaims oil from the suction cover and the evaporator. The suction cover eductor is discharged into the evaporator, and the evaporator eductor is discharged into the oil tank. The evaporator eductor line has a shut-off valve mounted on the evaporator.

The position of the shut-off valve will be set at two turns open during commissioning but may be adjusted later by a qualified technician as necessary for oil return. A normal operating setting for the valve may range from full closed to full open.

CVHH-SVX001G-EN

Oil supply to both the thrust bearing and journal bearings is cooled when the oil tank temperature reaches 140°F (60.0°C). The supply oil and liquid refrigerant are pumped to a brazed plate heat exchanger. The unit controller monitors oil tank temperature and opens a solenoid valve to allow liquid refrigerant to flow into the heat exchanger.

Motor Cooling System

Compressor motors are cooled with liquid refrigerant

(refer to the figure in

“Compressor Lubrication

System,” p. 78 ). The refrigerant pump is located on the

front of the oil tank (motor inside the oil tank). The refrigerant pump inlet is connected to the well at the bottom of the condenser. The well design ensures preferential supply of liquid refrigerant to the refrigerant pump before refrigerant is supplied to the economizer. Refrigerant is delivered to the motor via the pump. An in-line filter is installed (replace the inline filter only with major service). Motor refrigerant drain lines are routed to the condenser.

Tracer AdaptiView Display

Information is tailored to operators, service technicians, and owners.

When operating a chiller, there is specific information you need on a day-to-day basis—setpoints, limits, diagnostic information, and reports.

Day-to-day operational information is presented at the display. Logically organized groups of information— chiller modes of operation, active diagnostics, settings, and reports put information conveniently at your fingertips. For more information, refer to Tracer

AdaptiView Display for Water-Cooled CenTraVac

Chillers Operations Guide (CTV-SVU01*-EN).

RuptureGuard

Operation

The rupture disk monitors the pressure inside the chiller. If the pressure exceeds the disk’s burst setting, the disk ruptures, allowing the chiller pressure to enter the valve holder compartment upstream of the relief valve. If the pressure is above the pressure setting of the relief valve, the valve will open, allowing only the amount of refrigerant to escape to keep the pressure within safe operating limits.

The excess flow valve maintains the downstream side of the rupture disk at atmospheric pressure to assure proper operating conditions for the disk. When the disk bursts, the rapid pressure increase causes the excess flow valve to seal and the valve holder area becomes pressurized.

A disk rupture will be indicated by a pressure reading on the gauge and the pressure switch contacts will

CVHH-SVX001G-EN close. The pressure switch is an optional accessory and does not wire to the control panel. The pressure switch can be connected to a customer-supplied building automation system (BAS).

EarthWise Purge

General Information

Centrifugal chillers that use low-pressure refrigerants, such as R-1233zd, operate with areas of the chiller at less than atmospheric pressure. Non-condensables in the air, such as water and nitrogen vapor, may leak into these low-pressure areas and accumulate in the condenser. If these non-condensables are not removed, the condenser loses its ability to condense refrigerant efficiently and the pressure of the condenser increases. Increased condenser pressure lowers the chiller’s efficiency and capacity.

A purge system is required on low-pressure centrifugal chillers. It is a device that is externally mounted on the chiller. Its purpose is to remove non-condensable materials that have leaked into the machine.

describing non-condensables removed by the purge system, although any other noncondensable materials that may exist in the chiller are also removed by the purge system.

How a Purge System Works

From a functional standpoint, the purge system can be divided into subsystems of components. This section identifies and describes the function of these subsystems.

Refrigeration Circuit Subsystem

The purge evaporator of the refrigeration circuit is located in the purge tank. The purge tank is connected to the chiller condenser by supply and return lines through which chiller refrigerant can freely flow.

The purge evaporator coil presents a cold condensing surface to the chiller refrigerant entering the purge tank. When the purge refrigeration system is running, refrigerant from the chiller condenser is attracted to the cold surface of the purge evaporator. When the gaseous refrigerant contacts the surface of the purge evaporator coil, it condenses into a liquid, leaving a partial vacuum behind. More refrigerant vapor from the chiller condenser migrates to the purge tank to fill the vacuum.

The liquid refrigerant that has condensed in the purge tank returns to the chiller condenser through the liquid return line. The return line includes a filter-drier and a moisture-indicating sight glass.

The condensing unit is air-cooled and is operable whether the chiller is running or not. No additional cooling source is required.

81

3

4

5

6

7

8

2

1

=

q

1. Purge tank

2. Condensing unit (includes compressor, condenser coil, and fan)

3. Pressure-relief device (fusible plug)

4. Pump-out solenoid valve

5. Automatic expansion valve

6. Carbon tank

7. Carbon tank temperature sensor

8. Carbon tank heater

9. Exhaust solenoid valve

10. Pump-out compressor

11. Float switch

12. Compressor suction temperature sensor

13. Chiller refrigerant return line

14. Filter-drier canister w

82

0

9

CVHH-SVX001G-EN

4

3

2

1

5

9

6

7

8

0

-

1. Regeneration solenoid valve

2. Pressure-relief valve

3. Exhaust solenoid valve

4. Pump-out compressor

5. Carbon tank heater

6. Automatic expansion valve

7. Pump-out solenoid valve

8. Pressure-relief device (fusible plug)

9. Carbon tank

10. Purge tank

11. Condensing unit

12. Chiller refrigerant supply line

=

Purge Tank Subsystem

Any non-condensables that have accumulated from the refrigerant vapor are left behind to collect in the purge tank. As the quantity of non-condensables increases, the heat transfer efficiency of the purge evaporator coil is reduced, causing the purge compressor suction temperature to decrease.

CVHH-SVX001G-EN

A float switch, mounted in the bottom of the purge tank, indicates if there is excessive accumulation of liquid refrigerant in the tank. A liquid level sensor, which resides in the purge control panel, monitors the status of the float switch.

If the normally closed float switch is open for more than 20 minutes, the purge controls will turn off the

83

refrigeration system and generate a non-latching diagnostic—Purge Liquid Level Too High Warning. If the float switch has re-closed after 20 minutes, the purge controls will restart the refrigeration system.

If the float switch remains open for more than

20 minutes, or if the float switch/liquid level restart cycle has occurred more than four times in four hours, a latching diagnostic—Purge Liquid Level Too High

Continuously—will be generated. The purge system will not restart until it is reset.

If a Purge Liquid Level Too High Continuously diagnostic occurs, check the purge lines for any type of restriction (trapped liquid, closed valves, etc.) and ensure that the filter-drier on the liquid return line is in good condition.

A UL-required pressure-relief device (fusible plug), which protects against over-pressurization of the purge tank, is mounted on the purge tank. The plug material will fuse at 210°F (98.9°C), which equates to approximately 132 psig (910.1 kPaG) for refrigerant R-

1233zd.

Pump-out Subsystem

When the purge control subsystem detects the presence of non-condensables in the purge tank, the pump-out solenoid and exhaust solenoid valves open, and the pump-out compressor turns on. The valves and the compressor cycle on and off as needed to achieve an efficient and fast removal of non-condensables.

applications that require purge operation at low condensing temperatures and pressures. This option provides a two-stage pump-out compressor. The High Vacuum Pump option allows the purge system to operate to saturation temperatures as low as 34°F (1.1°C). Typical applications that may require the High Vacuum

Pump option include free-cooling installations, series chiller installations, ice systems having brine flowing through idle chillers, chillers installed outdoors or in unconditioned spaces, or any application that may cause very low condenser water temperatures.

Carbon Tank and Regeneration Subsystem

The discharge from the pump-out compressor is piped through the carbon tank. The special carbon in the tank effectively scrubs and collects refrigerant molecules from the non-condensable gas before the gas passes through the exhaust solenoid valve to the chiller vent line.

A 175 W resistive heater is mounted inside the carbon tank and is used to periodically “regenerate” the carbon bed and drive any collected refrigerant vapor back into the chiller. A UL-required pressure-relief valve, rated at 150 psig (1034.2 kPaG), is mounted on the line leaving the carbon tank. The valve protects against over-pressurization of the carbon tank.

84

A temperature sensor is installed through the top of the carbon tank shell so that the controls can monitor the carbon bed temperature. The temperature sensor controls the regeneration cycle and protect against overheating. If the limit temperature is reached, the system shuts down and a Purge Carbon Regen

Temperature Limit Exceeded diagnostic is generated.

Sensors

The following sensors are used to enable control communication between the Tracer ® UC800 controller and the EarthWise ™ purge system. The sensors use low-level intelligence devices (LLIDs) to communicate with the Tracer ® UC800 controller.

• C sensor is mounted on the purge condensing unit suction line. The controller uses the value of this temperature sensor to decide whether or not to purge non-condensables from the purge tank.

When the temperature drops to a specified point, the controller activates the pump-out cycle to remove the accumulated non-condensables from the purge tank. When enough non-condensables have been removed and the purge compressor suction temperature increases in response, the controller terminates the pump-out cycle.

• S sensor is mounted on the chiller. If the chiller is running, the controller uses the value of this temperature sensor to adjust the purge pump-out initiate/terminate setpoints. It may be used to prohibit pump-out if system conditions are too cool.

• S ap orra sensor is mounted on the chiller. If the chiller is off, the controller uses the value of this temperature sensor to adjust the purge pump-out initiate/ terminate setpoints. It may be used to prohibit pump-out if system conditions are too cool.

• C mounted in the carbon tank of the purge system. It provides feedback to the carbon regeneration algorithm. The sensor and the controller function much the same as a thermostat to control the carbon tank heater.

• L purge control panel. It monitors the status of the normally closed float switch, which is mounted in the bottom of the purge tank. If an adequate amount of liquid fails to drain from the purge tank, the float switch and sensor detect the condition and prevent further purge operation.

• C purge control panel. It uses a high-power relay to control the operation of the purge condensing unit.

• Q ua control panel. It has four relay outputs that are used to control the pump-out compressor, the carbon

CVHH-SVX001G-EN

tank heater, the regeneration solenoid valve, and an alarm output.

• D ua control panel. It has two triac-type outputs that are used to control the pump-out solenoid valve and the exhaust solenoid valve. The purge system draws its control power from the power supplies of the chiller control panel.

CVHH-SVX001G-EN 85

Start-up and Shut-down

This section provides basic information on chiller operation for common events.

Sequence of Operation

Adaptive control algorithms are used on CenTraVac ™ chillers. This section illustrates common control sequences.

Software Operation Overview Diagram

The following figure is a diagram of the five possible software states. This diagram can be thought of as a state chart, with the arrows and arrow text, depicting the transitions between states:

• The text in the circles are the internal software designations for each state.

Figure 51.

Software operation overview

• The first line of text in the circles are the visible top level operating modes that can be displayed in

Tracer ® AdaptiView ™ .

• The shading of each software state circle corresponds to the shading on the time lines that show the state that the chiller is in.

There are five generic states that the software can be in:

• Power Up

• Stopped

• Starting

• Running

• Stopping

Stopped

Stopped

Run Inhibit

Power

Up

Conf irmed

Shutdown

Diagnostic and

Res et

Stopping

Preparing to Shut Down

Shutting Down

Fast Restart or Satisfied Setpoint

Stop Command or Diagnostic

Stop

Comma

Diagnosti nd

Conf irmed

Sta rt c

Running

Running

Running—Limit

Starting

Auto

Waiting to Start

Starting Compressor

In the following diagrams:

• The time line indicates the upper level operating mode, as it would be viewed in the Tracer ®

AdaptiView ™ .

• The shading color of the cylinder indicates the software state.

86

• Text in parentheses indicates sub-mode text as viewed in the Tracer ® AdaptiView ™ .

• Text above the time line cylinder is used to illustrate inputs to the UC800. This may include user input to the Tracer ® AdaptiView ™ touch screen, control inputs from sensors, or control inputs from a generic BAS.

CVHH-SVX001G-EN

• Boxes indicate control actions such as turning on relays, or moving the inlet guide vanes.

• Smaller cylinders indicate diagnostic checks, text indicates time-based functions, solid double arrows indicate fixed timers, and dashed double arrows indicate variable timers.

Start-up Sequence of Operation—Wyedelta

Logic circuits within the various modules will determine the starting, running, and stopping operation of the chiller. When operation of the chiller is required, the chiller mode is set at “Auto.” Using customer-supplied power, the chilled water pump relay is energized and chilled water flow must be verified within 4 minutes and 15 seconds, at the same time the oil vent line valve is opened. The UC800 decides to start the chiller based on the differential to start setpoint. With the differential to start criteria met, the

UC800 then energizes condenser water pump relay

Figure 52.

Sequence of operation: power up to starting

Last Chiller Mode

Was Auto

Call for Cooling with customer-supplied power (refer to the following figure).

Based on the Restart Inhibit function and the

Differential to Start setpoint, the oil and refrigerant pump is energized, and the oil vent line valve is closed to the minimum position. The oil pressure must be at least 12 psid (82.7 kPaD) for 60 continuous seconds and condenser water flow verified within 4 minutes and

15 seconds for the compressor start sequence to be initiated. After the compressor starts, the oil vent line valve begins to open; it can take between 15 and

30 minutes to fully open depending on the chiller running conditions.

The compressor motor starts in the “Wye” configuration and then, after the compressor motor has accelerated and the maximum phase current has dropped below 85 percent of the chiller nameplate RLA for 1.5 seconds, the starter transitions to the “Delta” configuration.

Power

Applied to

Controls

Auto Waiting to Start

Waiting to Start

Starting

Compressor

UC800 Boot

Time

(30–50 sec)

Wait for Highest Motor Winding

Temp to Fall Below 165°F (73.9°C)

Enforce Power

Up Start Delay

Timer (0–30 min)

Energize Evaporator

Water Pump Relay

Wait for Oil Temp to Rise Above

Sat Evap + 30°F (16.7°C) and 100°F (37.8°C)

Prelube (60 sec)

Overdrive IGV Closed

Energize Condenser

Water Pump Relay

Begin Oil Vent Line

Valve low limit venting

Confirm Evaporator Water

Flow Within 4 min 15 sec

(6 sec Filter)

Confirm Condenser Water Flow

Within 4 min 15 sec

(6 sec Filter)

Energize Oil Pump Relay

Open Oil Vent Line Valve

Enforce Stop to Start Timer Using Values From

Real Time Clock (5–200 sec, 30 is Default)

Confirm 12 psid (82.7 kPaD)

Oil Pressure

Within 3 min

Check for High Vacuum

Lockout

Initialize Oil Vent Line Valve to Minimum Open Position

Now that the compressor motor is running in the

“Delta” configuration, the inlet guide vanes will modulate, opening and closing to the chiller load variation by operation of the stepper vane motor actuator to satisfy chilled water setpoint. The chiller

CVHH-SVX001G-EN continues to run in its appropriate mode of operation:

Normal, Softload, Limit Mode, and so on (refer to the following figure [running]). If the oil tank temperature rises above the oil cooler setpoint while the compressor is running, the oil cooler solenoid valve

87

shall be energized to cool the oil.

If the chilled water temperature drops below the chilled water setpoint by an amount set as the differential to stop setpoint, a normal chiller stop sequence is initiated as follows:

1. The inlet guide vanes are driven closed (up to

50 seconds).

2. After the inlet guide vanes are closed, the stop relay and the condenser water pump relays open to turn off. The oil and refrigerant pump motor will

Figure 53.

Sequence of operation: running

Starter

Status is

“Running”

Limit Mode

Starting

Compressor

Chiller Is Running continue to run for 3 minutes post-lube while the compressor coasts to a stop. The oil vent line valve will then open. The chilled water pump will continue to run while the UC800 monitors leaving chilled water temperature, preparing for the next compressor motor start based on the differential to start setpoint.

the following figure (satisfied setpoint) illustrates this sequence.

Chiller Is Running—Limit

Exit

Limit Mode

Chiller Is Running

Chiller

Is

Running

Modulate IGV/AFD for LWT control

Modulate IGV/AFD for Limit control

Modulate IGV/AFD for LWT control

Enforce All Running Mode Diagnostics

Note: If the Oil Tank Temperature rises above the Oil Cooler Control Setpoint whilte the compressor is running, the Oil Cooler Solenoid Valve shall be energized to cool the unit.

88 CVHH-SVX001G-EN

Figure 54.

Sequence of operation: satisfied setpoint

Satisfied Setpoint

Running

Preparing Shutdown

Shutting Down

Close IGV (0–50 sec) Postlube 3 min

Command IGV Closed

Shutting Down

De-Energize Oil Pump

Auto

Confirm No Oil Pressure*

5 min after oil pump is de-energized

Open Oil Vent Line Valve

De-Energize

Compressor

Confirm No Compressor Currents

Within 0–30 sec

Hold position of Oil Vent Line Valve

De-Energize Condenser

Water Pump Relay

*Note: No oil pressure is less than 3 psid (20.7 kPaD)

Enforce All Running Mode Diagnostics

If the STOP key is pressed on the operator interface, the chiller will follow the same stop sequence as described earlier except the chilled water pump relay will also open and stop the chilled water pump after the chilled water pump delay timer has timed out after compressor shut down (refer to the following figure

[normal shut-down to stopped and run inhibit]).

If the immediate stop is initiated, a panic stop occurs which follows the same stop sequence as pressing the

STOP key once, except the inlet guide vanes are not sequence-closed and the compressor motor is immediately turned off.

CVHH-SVX001G-EN 89

Figure 55.

Sequence of operation: normal shut-down to stopped and run inhibit

Local Stop

Normal Latching Diagnostic

Normal Non-Latching Diagnostic

Tracer Stop

External Auto-Stop

IGV Closed

Running Preparing Shutdown Shutting Down Shutting Down

Stopped

Run Inhibit

Stopped or

Run Inhibit

Evap Pump

Off Delay and Postlube

Complete

Close IGV (0–50 sec)

Command IGV Closed

Enforce All Running Mode Diagnostics

Power Up Diagram

“Software Operation Overview Diagram,” p. 86

includes an illustration of Tracer ® AdaptiView ™ during a power up of the UC800. This process takes from 30 to

50 seconds depending on the number of installed options.

Ice Machine Control

The control panel provides a service level Enable or

Disable menu entry for the Ice Building feature when the Ice Building option is installed. Ice Building can be entered from Front Panel or, if hardware is specified, the control panel will accept either an isolated contact closure 1K9 Terminals J2-1 and J2-2 (Ground) or a remote-communicated input (BAS) to initiate the ice building mode where the unit runs fully loaded at all times. Ice building will be terminated either by opening the contact or based on entering evaporator fluid temperature. The control panel will not permit the Ice

Building mode to be entered again until the unit is

Postlube 3 min Open Oil Vent Line Valve

De-Energize Oil Pump

De-Energize Condenser

Water Pump Relay

Evap Pump Off Delay Time

(0–30 min)

De-Energize

Compressor

Confirm No Compressor Currents

Within 8 sec

Hold position of Oil Vent Line Valve

Confirm No Oil Pressure*

5 min after oil pump is de-energized

De-Energize Evaporator

Water Pump Relay

*Note: No oil pressure is less than 3 psid (20.7 kPaD) switched to the non-ice building mode and back into the ice building mode. It is not acceptable to reset the chilled water setpoint low to achieve a fully loaded compressor. When entering ice building, the compressor will be loaded at its maximum rate and when leaving ice building, the compressor will be unloaded at its maximum rate. While loading and unloading the compressor, all surge detection will be ignored. While in the ice building mode, current limit setpoints less than the maximum will be ignored. Ice

Building can be terminated by one of the following means:

• Front panel disable

• Opening the external ice contacts/remotecommunicated input (BAS)

• Satisfying an evaporator entering fluid temperature setpoint (default is 27°F [-2.8°C])

• Surging for seven minutes at full open inlet guide vanes (IGV)

90 CVHH-SVX001G-EN

Figure 56.

Sequence of operation: ice building: running to ice building

Ice Making Command:

1. Front Panel

2. Tracer

3. External Input

Ice Making

Command

Withdrawn

Running

Running

(Ice Building)

Running (Ice to Normal

Transition)

Evap Leaving

Water Temp Rises

Above the Diff To

Stop

Running

Open IGV at Max Rate/

Max AFD Frequency

Ignore Softloading and

Set CLS=100%

Energize Ice Building

Relay

Ice to Normal Transition Timer

(0–10 min)

Close IGV/Min AFD

Frequency

De-Energize Ice Building

Relay

Head Relief Request Relay

Delay (1–60 min)

Energize Head Relief

Request Relay

Head Relief Request Relay

Delay (1–60 min)

Enforce All Limits and Running Mode Diagnostics

Modulate IGV/AFD for LWT control

De-Energize Head Relief

Request Relay

Running

CVHH-SVX001G-EN 91

Figure 57.

Sequence of operation: ice building: stopped to ice to ice building complete

Ice Making Command:

1. Front Panel

2. Tracer

3. External Input

Evap Entering

Water Temp Falls

Below the Ice

Termination

Setpoint

Auto

Starting

Compressor

Running

(Ice Building)

Open IGV at Max Rate/

Max AFD Frequency

Preparing to

Shut Down

Close IGV

(0–50 sec)

Close IGV/Min AFD

Frequency

Shutting

Down

Postlube

(3 min)

Run

Inhibit

Run Inhibit

(Ice Building

Complete)

De-Energize Oil Pump

Open Oil Vent Line Valve

Ignore Softloading and

Set CLS=100%

Energize Ice Building

Relay

Begin Oil Vent Line

Valve low limit venting

Heat Relief Request Relay

Delay (1–60 min)

De-Energize Ice

Building Relay

Hold position of Oil Vent Line Valve

De-Energize Heat

Relief Request Relay

Energize Head Relief

Request Relay

De-Energize

Condenser

Water Pump Relay

Ignore Evap Pump

Off Delay Time for Ice Building

De-Energize

Compressor

De-Energize Evaporator

Water Pump Relay

Enforce All Limits and Running Mode Diagnostics

Confirm No Compressor Currents

Within 8 sec

Free Cooling Cycle

Based on the principle that refrigerant migrates to the coldest area in the system, the free cooling option adapts the basic chiller to function as a simple heat exchanger. However, it does not provide control of the leaving chilled water temperature.

If condenser water is available at a temperature lower than the required leaving chilled water temperature, the operator interface must remain in AUTO and the operator starts the free cooling cycle by enabling the

Free Cooling mode in the Tracer ® AdaptiView ™

Feature Settings group of the operator interface, or by means of a BAS request. The following components must be factory- or field-installed to equip the unit for free cooling operation:

• a refrigerant gas line, and electrically-actuated shutoff valve, between the evaporator and condenser, and

• a valved liquid return line, and electrically-actuated shutoff valve, between the condenser sump and the evaporator.

When the chiller is changed over to the free cooling mode, the compressor will shut down if running and the shutoff valves in the liquid and gas lines open; unit control logic prevents the compressor from energizing

92 during free cooling. Since the temperature and pressure of the refrigerant in the evaporator are higher than in the condenser (i.e., because of the difference in water temperature), the refrigerant in the evaporator vaporizes and travels to the condenser, cooling tower water causes the refrigerant to condense on the condenser tubes, and flow (again, by gravity) back to the evaporator.

This compulsory refrigerant cycle is sustained as long as a temperature differential exists between condenser and evaporator water. The actual cooling capacity provided by the free cooling cycle is determined by the difference between these temperatures which, in turn, determines the rate of refrigerant flow between the evaporator and condenser shells.

If the system load exceeds the available free cooling capacity, the operator must manually initiate changeover to the mechanical cooling mode by disabling the free cooling mode of operation. The gas and liquid line valves then close and compressor operation begins (refer to the figure in

“Start-up

Sequence of Operation—Wye-delta,” p. 87

[power up to starting], beginning at Auto mode). Refrigerant gas is drawn out of the evaporator by the compressor, where it is then compressed and discharged to the condenser.

CVHH-SVX001G-EN

Hot Water Control

Occasionally, CenTraVac ™ chillers are selected to provide heating as a primary mission. With hot water temperature control, the chiller can be used as a heating source or cooling source. This feature provides greater application flexibility. In this case, the operator selects a hot water temperature and the chiller capacity is modulated to maintain the hot water setpoint.

Heating is the primary mission and cooling is a waste product or is a secondary mission. This type of operation requires an endless source of evaporator load (heat), such as well or lake water. The chiller has only one condenser.

convert the chiller to a heat pump. Heat pump refers to the capability to change from a coolingdriven application to a heating-driven application by changing the refrigerant path on the chiller.

This is impractical for centrifugal chillers as it would be much easier to switch over the water side.

This is NOT heat recovery. Although this feature could be used to recover heat in some form, a heat recovery unit has a second heat exchanger on the condenser side.

The Tracer ® AdaptiView ™ provides the Hot Water

Temperature Control mode as standard. The leaving condenser water temperature is controlled to a hot water setpoint between 80°F and 140°F (26.7°C and

60.0°C). The leaving evaporator water temperature is left to drift to satisfy the heating load of the condenser.

In this application, the evaporator is normally piped into a lake, well, or other source of constant temperature water for the purpose of extracting heat.

In Hot Water Temperature Control mode, all the limit modes and diagnostics operate as in normal cooling with one exception: the leaving condenser water temperature sensor is an MMR diagnostic when in Hot

Water Temperature Control mode. (It is an informational warning in the Normal Cooling mode.)

In the Hot Water Temperature Control mode, the differential-to-start and differential-to-stop setpoints are used with respect to the hot water setpoint instead of with the chilled water setpoint. The control panel provides a separate entry at the Tracer ® AdaptiView ™ to set the hot water setpoint; Tracer ® AdaptiView ™ is also able to set the hot water setpoint. In the Hot Water mode, the external chilled water setpoint is the external hot water setpoint; that is, a single analog input is shared at the 1K6-J2-5 to 6 (ground).

An external binary input to select external Hot Water

Control mode is on the EXOP OPTIONAL module 1K8 terminals J2-3 to J2-4 (ground). Tracer ® AdaptiView ™ also has a binary input to select chilled water control or hot water temperature control. There is no additional leaving hot water temperature cutout; the HPC and condenser limit provide for high temperature and pressure protection.

CVHH-SVX001G-EN

In Hot Water Temperature Control, the softloading pulldown rate limit operates as a softloading pullup rate limit. The setpoint for setting the temperature rate limit is the same setpoint for normal cooling as it is for hot water temperature control. The hot water temperature control feature is not designed to run with

HGBP, AFD, free cooling, or ice-building.

The factory set PID tuning values for the leaving water temperature control are the same settings for both normal cooling and hot water temperature control.

Control Panel Devices and Unit-

Mounted Devices

Unit Control Panel

Safety and operating controls are housed in the unit control panel, the starter panel, and the purge control panel. The control panel operator interface and UC800 is called Tracer ® AdaptiView ™ and is located on an adjustable arm connected to the base of the control panel. For more information about operating Tracer ®

AdaptiView ™ , refer to Tracer AdaptiView Display for

Water-Cooled CenTraVac Chillers Operations Guide

(CTV-SVU01*-EN).

The control panel houses several other controls modules called panel-mounted Low Level Intelligent

Devices (LLIDs), power supply, terminal block, fuse, circuit breakers, and transformer. The inter-processor communication (IPC) bus allows the communications between LLIDs and the UC800. Unit-mounted devices are called frame-mounted LLIDs and can be temperature sensors or pressure transducers. These and other functional switches provide analog and binary inputs to the control system.

User-Defined Language Support

Tracer ® AdaptiView ™ is capable of displaying English text or any of 26 other languages. Switching languages is simply accomplished from a Language Settings menu. The following languages are available:

• Arabic (Gulf Regions)

• Chinese—China

• Chinese—Taiwan

• Czech

• Dutch

• English

• French

• French (Canada)

• German

• Greek

• Hebrew

• Hungarian

• Indonesian

93

• Italian

• Japanese

• Korean

• Norwegian

• Polish

• Portuguese (Portugal)

• Portuguese (Brazil)

• Russian

• Romanian

• Spanish (Europe)

• Spanish (Latin America)

• Swedish

• Thai

Unit Start-up and Shut-down

Procedures

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94 CVHH-SVX001G-EN

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

Daily Unit Start-up

1. Verify the chilled water pump and condenser water pump starter are in ON or AUTO.

2. Verify the cooling tower is in ON or AUTO.

3. Check the oil tank oil level; the level must be visible in or above the lower sight glass. Also, check the oil tank temperature; normal oil tank temperature before start-up is 128°F to 133°F (53.3°C to 56.1°C).

4. Check the chilled water setpoint and readjust it, if necessary, in the Chiller Settings menu.

5. If necessary, readjust the current limit setpoint in the Chiller Setpoints menu.

6. Press AUTO.

The control panel also checks compressor motor winding temperature and a start is initiated after a minimum restart inhibit time if the winding temperature is less than 265°F (129.4°C). The chilled water pump relay is energized and evaporator water flow is proven. Next, the control panel checks the leaving evaporator water temperature and compares it

CVHH-SVX001G-EN to the chilled water setpoint. If the difference between these values is less than the start differential setpoint, cooling is not needed.

If the control panel determines that the difference between the evaporator leaving water temperature and chilled water setpoint exceeds the start differential setpoint, the unit enters the initiate Start Mode and the oil and refrigerant pump and the condenser water pump are started. If flow is not initially established within 4 minutes 15 seconds of the condenser pump relay energization, an automatically resetting diagnostic “Condenser Water Flow Overdue” shall be generated, which terminates the prestart mode and deenergizes the condenser water pump relay. This diagnostic is automatically reset if flow is established at any later time.

Tracer ® AdaptiView ™ is in control of the condenser pump through its condenser pump relay, since it is commanded off at the time of the diagnostic. It may reset and allow normal chiller operation if the pump was controlled from some external source.

If the compressor motor starts and accelerates successfully, Running appears on the display. If the purge is set to AUTO, the purge will start running and will run as long as the chiller is running.

during start-up, unit operation will be locked out and a manual reset is required before the startup sequence can begin again. If the fault condition has not cleared, the control panel will not permit restart.

When the cooling requirement is satisfied, the control panel originates a Shutting down signal. The inlet guide vanes are driven closed for 50 seconds, the compressor stops, and the unit enters a 3-minute postlube period. The evaporator pump may continue to run for the amount of time set using Tracer ® AdaptiView ™ .

After the post-lube cycle is done, the unit returns to auto mode.

Seasonal Unit Start-up

1. Close all drain valves, and reinstall the drain plugs in the evaporator and condenser headers.

2. Service the auxiliary equipment according to the start-up and maintenance instructions provided by the respective equipment manufacturers.

3. Fill and vent the cooling tower, if used, as well as the condenser and piping. At this point, all air must be removed from the system (including each pass).

Then, close the vents in the condenser waterboxes.

4. Open all of the valves in the evaporator chilled water circuit.

5. If the evaporator was previously drained, fill and vent the evaporator and chilled water circuit. After

95

all air is removed from the system (including each pass), close the vent valves in the evaporator waterboxes.

6. Lubricate the external vane control linkage as needed.

7. Check the adjustment and operation of each safety and operating control.

8. Close all disconnect switches.

9. Perform instructions listed in

“Daily Unit Startup,” p. 95 .

Daily Unit Shut-down

“Start-up Sequence of Operation—Wye-delta,” p.

87

.

1. Press STOP.

2. After compressor and water pumps shut down, the operator may turn Pump Contactors to OFF or open pump disconnects.

Seasonal Unit Shut-down

remain closed to allow oil sump heater operation. Failure to do this will allow refrigerant to condense in the oil pump.

1. Open all disconnect switches except the control power disconnect switch.

2. Drain the condenser piping and cooling tower, if used. Rinse with clean water.

3. Remove the drain and vent plugs from the condenser headers to drain the condenser. Air-dry bundle of residual water.

4. Once the unit is secured for the season, the maintenance procedures described in

“Normal

Operation,” p. 106

(tables for recommended maintenance of standard and optional features) should be performed by qualified Trane service technicians.

operate the purge unit for a two-hour period every two weeks. This will prevent the accumulation of air and non-condensables in the machine. To start the purge, change the purge mode to ON in the unit control “Settings Purge” menu. Remember to turn the purge mode to

“Adaptive” after the two-hour run time.

EarthWise Purge

Sequence of Operations

A Tracer ® UC800 controller that is configured to control a purge system uses the operational sequences described in this section.

96

Purge Operating Modes

Purge operating mode options are as follows:

• S this mode.

• O n.. The purge condensing unit runs continuously in this mode, regardless of the chiller’s operational status.

• A if the main compressor of the chiller is operating.

• A depends on past purge activity.

Adaptive Mode

The objectives of operating the unit in the Adaptive mode are to:

• Enable purge system operation.

• Enable the refrigeration circuit to effectively accumulate non-condensables whether or not the chiller is running.

• Provide information to an operator regarding whether leakage is on the high-pressure or lowpressure side of the chiller.

• Decrease energy usage by running the purge refrigeration circuit only when needed to remove non-condensables, rather than running it continuously.

The Adaptive mode requires historical operating data so that the controller can make optimal decisions regarding how to run the purge refrigeration circuit in the future. On initial start-up of a chiller that is in

Adaptive mode, the purge refrigeration circuit runs continuously for 168 hours (7 days). The chiller compressor may or may not be running during this period.

Following the initial data collection period, the

Adaptive mode customizes the purge refrigeration circuit operation during two distinct chiller operating conditions:

• Chiller compressor On

• Chiller compressor Off

Adaptive Mode Process—Chiller Compressor On

The following figure illustrates the process described in this subsection.

When the chiller compressor starts, the purge refrigeration circuit starts. The purge refrigeration circuit continues to run until 60 consecutive minutes of running occur without any pump-out of noncondensables. The Pumpout Time is the greater of the following two values that the controller has been tracking:

• The pump-out time with the chiller On, over the last

24 hours

CVHH-SVX001G-EN

• The average daily pump-out time with the chiller

On, over the last 7 days

Figure 58.

Adaptive chiller ON flow chart

First chiller power-up.

Purge operates continuously for 168 hours to collect data.

Chiller On or Off.

Chiller and purge start.

Purge runs.

No

Has purge run 60 minutes without any pump-out?

Yes

The purge control reviews the historical data and determines the Pumpout

Time with the chiller On

(Pumpout Time from last

24 hours daily average over last 7 days, whichever is greater.

Yes

Is Pumpout

Time greater than 8 minutes?

Turn purge unit Off for

1 hour, then restart.

Yes

Is Pumpout

Time greater than 5 minutes?

No

Turn purge unit Off for

2 hours, then restart.

Yes

Is Pumpout

Time greater than 3 minutes?

No

Turn purge unit Off for

3 hours, then restart.

Yes

Is Pumpout

Time greater than 1 minute?

No

Turn purge unit Off for

4 hours, then restart.

The purge then shuts down for a corresponding period of time, as shown in the following table:

No

Pumpout Time with chiller

On (over the last 24 hours or daily average over the last 7 days, whichever is greater)

Pumpout Time ≤ 1 minute

1 minute < Pumpout Time ≤ 3 minutes

3 minutes < Pumpout Time ≤ 5 minutes

5 minutes < Pumpout Time ≤ 8 minutes

Pumpout Time > 8 minutes

Purge Off cycle duration

4 hours

3 hours

2 hours

1 hour

No Off cycle

CVHH-SVX001G-EN 97

During the purge refrigeration circuit Off cycle, the time remaining is displayed as Time Until Next Purge Run in the Log Sheet that you can view from the Tracer ®

AdaptiView ™ display.

If the compressor is turned Off during the purge refrigeration circuit Off cycle, the purge transfers to

Adaptive Mode Procedure—Chiller Compressor

Off.

“Adaptive Mode Procedure—Chiller Compressor

Off,” p. 98

includes an illustration of this process.

Adaptive Mode Procedure—Chiller Compressor

Off

Refer to the following figure for an illustration of the process described in this subsection.

Figure 59.

Adaptive chiller OFF flow chart

First chiller powerup. Purge operates continuously for 168 hours to collect data.

Chiller On or Off.

Chiller Off.

Purge Off.

If the chiller compressor is turned Off, the purge refrigeration circuit Off cycle is determined by the purge control. The purge Off-cycle duration is determined by the pump-out time, which is the greater of the following two values:

• Daily Pumpout—24 hours (the pump-out time over the last 24 hours whether the chiller is On or Off)

• Average Daily Pumpout—7 days (the pump-out time with the chiller On over the last 7 days) otte ®

AdaptiView ™ display.

The purge control reviews the historical pump-out data for

“chiller On” and “chiller Off” and determines the Pumpout Time

(from the last 24 hours, or the daily average over the last 7 days, whichever is greater).

Turn purge Off.

Hold purge Off for 6 hours.

No

Is Pumpout

Time less than

5 minutes?

Yes

No

Is purge running for

60 minutes without purging?

Yes

Hold purge Off for 1 day.

No

Is Pumpout

Time less than

3 minutes?

Run purge.

Yes

Hold purge Off for 2 days.

No

Is Pumpout

Time less than

1 minute?

Yes

Hold purge Off for 3 days.

The purge will be shut down for a corresponding period of time, as shown in the following table:

98 CVHH-SVX001G-EN

Pumpout Time with chiller On or Off

(over the last 24 hours or daily average over the last 7 days, whichever is greater)

Pumpout Time ≤ 1 minute

1 minute < Pumpout Time ≤ 3 minutes

3 minutes < Pumpout Time ≤ 5 minutes

Pumpout Time > 5 minutes

Purge Off cycle duration

3 days

2 days

1 day

6 hours

During the purge refrigeration circuit Off cycle, the time remaining is displayed as the Time Until Next Purge

Run in the purge report of the Tracer ® AdaptiView ™ display.

If the controls determine it is necessary to run the purge while the chiller compressor is Off, the purge will be started and run until 60 consecutive minutes have passed without any pump-out of non-condensables.

If the chiller compressor starts before the purge Off cycle has elapsed, the purge starts and transfers to

Adaptive Mode Procedure—Chiller Compressor On.

“Adaptive Mode Process—Chiller Compressor On,” p.

96

includes an illustration of this process.

Submodes

You can view submodes from the Purge Settings screen. The available purge submodes are:

• R condensing unit/compressor is operating.

• R condensing unit/compressor is not operating.

• P circuit is On and pump-out has been initiated by the purge unit controls.

• E been initiated by an operator.

• P refrigeration circuit is On but pump-out has been inhibited by a low condenser saturation temperature.

• D purge refrigeration circuit is On but the daily pumpout limit has been disabled.

• R eg en is in its regeneration mode. Pump-out is not allowed in this submode.

• A diagnostic occurs.

• P Diia g S system has shut down in response to a latching diagnostic.

• R eg en not allowed.

Typical Purge Refrigeration Circuit Operating

Cycle

The purge condensing-unit compressor suction temperature varies with the amount of noncondensables collected in the purge tank. If the amount of non-condensables collected in the purge tank limits the available condensing surface in the tank, the condensing-unit compressor suction temperature begins to fall.

The purge controller initiates a pump-out cycle when the suction temperature reaches the pump-out initiate value that is calculated within the purge control. During the pump-out cycle, the small pump-out compressor pulls any non-condensables from the purge tank and discharges them through the carbon tank. As the noncondensables are removed from the purge tank, the condensing-unit compressor suction temperature increases. The purge controller monitors the compressor suction temperature and cycles or stops the pump-out, depending on the temperature that is present.

The 1/4 hp air-cooled condensing unit of the refrigeration system operates effectively when it is in the operating range shown in the following figure.

CVHH-SVX001G-EN 99

Figure 60.

Purge operating limits

120 (48.8)

100 (37.8)

Operating envelope extremes

80 (26.7)

Typical operation

60 (15.6)

40 (4.4)

20 (-6.7)

0 (-17.8)

0

(-17.8)

20

(-6.7)

40

(4.4)

60

(15.6)

80

(26.7)

100

(37.8)

120

(48.8)

140

(60.0)

160

(71.1)

Pumpout can be inhibited in this range according to control settings.

Chiller Condenser Saturation Temperature, °F (°C)

Air Removal

If no air is in the purge tank, the refrigerant returning to the purge condensing unit compressor suction has a high superheat (heat added past the point of evaporation), because of the heat removed from the condensing chiller refrigerant vapor in the purge tank.

As air accumulates in the purge tank, it displaces the chiller refrigerant vapor and decreases the amount of coil surface that is exposed to the vapor. Less heat is removed from the vapor, and the available superheat at the purge condensing unit compressor suction consequently falls. When the purge refrigerant compressor suction temperature falls far enough to reach the pump-out initiate value, the purge control activates the solenoids and the pump-out compressor to remove the accumulated air.

As air is removed from the purge tank, the inside coil is once again exposed to chiller refrigerant vapor. As more chiller refrigerant vapor condenses on the coil, more heat is removed from the vapor, and the purge refrigerant compressor suction temperature rises. The purge control cycles or stops the pump-out process in response to the compressor suction temperature.

Pump-out Operating Sequence

As the purge control system detects the presence of non-condensables in the purge tank, it initiates a pump-out cycle. The pump-out solenoid valve, the exhaust solenoid valve, and the pump-out compressor cycle On and Off as needed to remove the noncondensables.

Non-condensable Pump-out Algorithm

The controller uses the non-condensable pump-out algorithm to determine when to initiate, control, and terminate a pump-out cycle to remove air from the purge tank. The purge refrigerant compressor suction

100 temperature sensor serves as the feedback to this control algorithm. The compressor suction temperature pump-out initiate and pump-out terminate values are calculated by the purge control and are a function of the purge liquid temperature.

The refrigerant used in the purge refrigeration circuit,

R-513A, is metered into the purge tank coil by a constant-pressure regulating expansion valve. The valve automatically controls the purge suction pressure at a constant value of 21.5 psia (148.2 kPaA). Therefore, refrigerant is metered into the coil as a two-phase refrigerant mixture at a constant saturation temperature of approximately -3°F (-19.4°C).

The cold coil creates a low vapor pressure near its outside surface, which draws refrigerant from the chiller condenser into the purge tank and to the coil surface. When the refrigerant gets close enough to the coil surface, it condenses into a liquid. Since liquid refrigerant requires less volume than it does in a gaseous form, additional refrigerant enters the purge tank to fill the void and, in turn, condenses. This mechanism is known as a thermal siphon .

As the chiller refrigerant condenses, heat is transferred into the purge coil through the latent heat of condensation. The compressor suction temperature sensor monitors this heat transfer.

Air and other gases carried with the chiller refrigerant vapor do not condense on the coil. Instead, they accumulate in the purge tank, effectively acting to insulate and inhibit the flow of refrigerant to the cold coil surface. The thermal siphon rate is reduced and, consequently, so is the amount of heat transfer. A corresponding reduction occurs in the temperature of the purge refrigerant exiting the coil. The compressor suction temperature sensor monitors this temperature.

CVHH-SVX001G-EN

When sufficient non-condensables have accumulated in the purge tank to decrease the compressor suction temperature below the pump-out initiate value, a pump-out cycle begins. The cycle is terminated when the compressor suction temperature sensor increases above the pump-out terminate value. The calculations for the pump-out values are:

Pump-out initiate:

• (°F) = Purge liquid temperature (°F) – 50°F, or 0°F

(whichever is higher)

• (°C) = Purge liquid temperature (°C) – 10.0°C, or

-17.8°C (whichever is higher)

Pump-out terminate:

• (°F) = Purge liquid temperature (°F) – 40°F, or 5°F

(whichever is higher)

• (°C) = Purge liquid temperature (°C) – 4.4°C, or -

15.0°C (whichever is higher)

The purge liquid temperature value comes from the chiller’s saturated condenser temperature sensor when the chiller is running, or the chiller’s saturated evaporator temperature sensor when the chiller is off.

Non-condensable Pump-out cycle

A non-condensable pump-out cycle may be initiated as described below only if the following two conditions are met:

• a carbon regeneration cycle is NOT in process, and

• the refrigeration circuit is on.

If at any time, except as described above, the purge refrigerant compressor suction temperature drops below the pump-out initiate value, the following sequence is initiated by the controls.

The controller starts the pump-out compressor and opens the exhaust solenoid valve. After 5 seconds, the pump-out solenoid valve opens and pulses at a rate of

20 seconds On and 20 seconds Off. If after two cycles, the purge refrigerant compressor suction temperature has not exceeded the pump-out terminate value, the pump-out solenoid valve stays continuously open. If the pump-out compressor runs for more than

10 consecutive minutes, the controller recalculates the pump-out initiate and pump-out terminate values as described.

The purge controls continue to operate the pump-out solenoid valve and calculate values as described above until the purge refrigerant compressor suction temperature rises above the pump-out terminate value.

At this point, the controller will close the pump-out solenoid valve and turn off the pump-out compressor and exhaust solenoid valve.

CVHH-SVX001G-EN pump-out compressors, operation at low chiller condenser saturation temperatures may result in a system vacuum greater than the pump-out compressor can overcome. If the chiller experiences low condensing temperatures, then the Tracer ® UC800 controller can be programmed to inhibit the operation of the purge pump-out compressor.

Carbon Tank and Regeneration

Subsystem

The function of the carbon tank is to absorb refrigerant molecules that may be entrained in the discharge of non-condensables. In order to maintain effectiveness, the carbon tank periodically regenerates.

Carbon Regeneration Algorithm

The controller uses the carbon regeneration algorithm to determine when to initiate, control, and terminate a carbon regeneration cycle. The carbon bed temperature sensor serves as the feedback to this algorithm. In addition, the controller uses a pump-out accumulation timer to indicate the remaining carbon capacity in the carbon tank. The carbon capacity is the capacity of the carbon to adsorb refrigerant while maintaining acceptable levels of refrigerant emission through the chiller vent line. A capacity of 100 percent means the carbon bed has the capacity to adsorb refrigerant and maintain acceptable emission levels. A capacity of 0 percent means the carbon bed has inadequate capacity to adsorb refrigerant and still maintain acceptable emission levels.

The main objectives of the carbon regeneration algorithm are to:

• Minimize the amount of refrigerant contained in the carbon by performing a periodic regeneration.

• Regenerate to maintain low emissions levels.

• Minimize the regeneration time.

• Regenerate only when the chiller is at a minimum level of purging activity.

• Allow regeneration to occur with the chiller On or

Off. Regeneration is preferable when the chiller is

On to ensure low carbon tank pressure, but regeneration is also acceptable when the chiller is

Off.

The remaining amount of adsorption capacity within the carbon tank is directly proportional to the number of purge pump-out minutes that have accumulated, and is also a function of the chiller refrigerant type. The purge carbon tank on an R-1233zd-equipped chiller is considered to be fully saturated after the purge has accumulated 350 minutes of pump-out time. Because the relationship between pump-out capacity and pump-out minutes is directly proportional, it can be described by the following equation within the regeneration algorithm:

101

Remaining carbon capacity% =

100 - (pump-out minutes since last regen/pump-out minutes at 100% capacity)*100

For example, an R-1233zd-equipped chiller that has accumulated 80 minutes of purge pump-out time since the last carbon tank regeneration would be estimated to have 84 percent carbon tank capacity remaining:

100 – (80/500)*100 = 84%

The purge controls may initiate a carbon tank regeneration cycle when the remaining carbon tank capacity is calculated to be less than 80 percent.

However, the continued stable operation of the chiller is always more important than the regeneration of the carbon tank. Therefore, the following rules apply:

1. If the Daily Pump-out Limit is disabled, a regeneration cycle may not be initiated, regardless of the value of the remaining carbon capacity.

Also, if the Daily Pump-out Limit is disabled during a regeneration cycle, the regeneration cycle must be terminated.

2. When the remaining carbon capacity is less than

80 percent, a regeneration cycle will be initiated at the next opportunity when the chiller is running

(after the chiller has started and no pump-out minutes have accumulated for the previous

60 minutes).

3. If there is no opportunity to purge as indicated by

Rules 1 and 2 and the remaining carbon capacity is less than 50 percent, a regeneration cycle will be initiated at the best opportunity when the chiller is shut down (and no pump-out minutes have accumulated for the previous 60 minutes).

4. If there is no opportunity to regenerate as indicated by Rules 1, 2, and 3 and the carbon capacity drops below 0 percent, then a regeneration cycle is initiated.

5. Note that, if at any time during the regeneration cycle the chiller is running and shuts down or if the chiller is off and starts up, then the regeneration cycle is continued.

Carbon Tank Regeneration Sequence

102 n d ea na ve viicciin g.. F

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

If the purge controller determine that carbon tank regeneration is desired and is allowed, the purge controls:

1. Disable the purge refrigeration circuit and the pump-out solenoid valve.

2. Open the regeneration solenoid valve and turn on the carbon tank heater.

3. Monitor the carbon temperature until it reaches the regeneration temperature value of 240°F (115.6°C), and control within a ±10°F (5.6°C) dead band for

15 minutes (this step should take approximately three hours).

• If the carbon tank temperature does not increase more than 25°F (13.9°C) in the first two hours, the controller generates a non-latching diagnostic, Carbon Regeneration Temperature

Too Low, and indicates a status of Carbon

Regeneration Disabled. The purpose of this diagnostic is to identify a failed heater or temperature sensor. It prevents automatic regeneration from occurring, but a service technician can initiate a manual regeneration for

CVHH-SVX001G-EN

testing purposes. All other purge algorithms continue to function.

• If the carbon tank temperature does not reach the regeneration temperature setpoint minus

30°F (16.7°C) within four hours, the controller generates a non-latching diagnostic Purge

Carbon Regeneration Temperature Not

Satisfied. The purpose of this diagnostic is to identify a failing insulation system. All purge functions remain active.

• If the carbon temperature exceeds 120 percent of the regeneration temperature setpoint, the controller issue a latching diagnostic, Purge

Carbon Regeneration Temperature Limit

Exceeded. The purpose of this diagnostic is to identify a failed heater relay or temperature sensor. It disables the purge and open the exhaust solenoid valve.

4. Close the regeneration solenoid valve and turn off the heater.

5. The carbon capacity is reset to 100 percent.

6. The purge refrigeration circuit is turned on to allow the carbon tank to cool for 4 hours or until the carbon temperature reaches 100°F (37.8°C), whichever comes first.

• If the carbon temperature does not decrease more than 25°F (13.9°C) in the first hour, the controller generates a latching diagnostic Purge

Regeneration Cooldown Temp Too High. The purpose of this diagnostic is to identify a failed heater relay or temperature sensor. The diagnostic will disable the purge and open the exhaust solenoid valve.

7. The exhaust solenoid will open for 5 minutes and then close.

8. The refrigeration circuit is run for 15 minutes and allows pumpouts during this time.

• A small amount of non-condensable gas resident in the carbon tank will be returned to the chiller during a regeneration cycle.

Operating the refrigeration circuit during the carbon cool-down cycle will allow time to accumulate this gas in the purge tank in readiness for the non-condensable pumpout controls to be reactivated following completion of the cool down cycle.

The complete regeneration cycle can take as long as seven hours to accomplish but an average chiller does not have to regenerate very often. A typical regeneration cycle is depicted in the following figure.

CVHH-SVX001G-EN

Figure 61. Typical carbon regeneration cycle

0 2 4

Time (Hours)

6 8

Purge Status Points component screen of the Tracer ® AdaptiView ™ display. The purge component screen is accessible from the purge touch target on the home screen of the display.

• T is in Adaptive mode and is idle. It indicates the amount of time left on the adaptive cycle timer.

• D 4 H urrss.. Indicates the daily pumpout time for the last 24 hours (a moving 24hour window). It indicates how the hermetic integrity of the chiller compares to historic pumpout times for the same chiller. It also allows a check against factory-recommended values.

• A average daily pump-out time for the last 168 hours

(a moving 168-hour window). It enables a comparison of present pump-out times to past averages, and can be another indication of the hermetic integrity of the chiller.

• D menu. When the daily pumpout rate exceeds this value, purge operation stops and a diagnostic is generated.

• C time during the past seven days (floating 168-hour window) that the chiller was operating. You can use it to help determine if a leak is present on the high side or the low side of the chiller.

• P percentage of the total purge pump-out time during

103

the past seven days that occurred while the chiller was operating. You can use it to help determine if a leak is present on the high side or the low side of the chiller.

• P percentage of the total purge pump-out time during the past seven days that occurred when the chiller was not operating. You can use it to help determine if a leak is present on the high side or the low side of the chiller.

• P time that has accumulated over the life of the purge.

• P purge refrigerant compressor suction temperature.

It is useful for diagnosing purge system problems.

• P sensed by the controller and used to inhibit purge operation. The purge liquid temperature sensor, when the chiller is operating, is the chiller saturated condenser temperature sensor; when the chiller is

Off, it is the chiller saturated evaporator temperature sensor. If this temperature is below the

Pumpout Inhibit Temperature that is defined in the value is used to prevent inefficient operation of the purge under certain conditions.

• C arrb temperature and is useful for monitoring regeneration and for diagnosing regeneration system problems.

104 CVHH-SVX001G-EN

Recommended Maintenance

viicciin g cco ott b e iin an d d viicciin g.. F de d b arrtt//rru n an d cco orr p urrg ag e..

ad diittiio ap acciitto application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

CVHH-SVX001G-EN

X39003892001A an e C uiip me an e ® rre an e a

This section describes the basic chiller preventive maintenance procedures, and recommends the intervals at which these procedures should be performed. Use of a periodic maintenance program is important to ensure the best possible performance and efficiency from a CenTraVac ™ chiller.

CVHH CenTraVac ™ chillers, the bolts used for both the economizer sump cover and the oil tank cover are specified for both ASME and PED application (SCREW, METRIC CAP-M16 x 70 mm with FULL THREAD), HEAVY HEXAGON HEAD -

ASME SA-193M GRADE B7, ZINC PLATED.

representative for replacement bolts.

This chiller utilizes Refrigerant Grade R-1233zd. Contact your local Trane Service Agency for proper refrigerant:

• Refrigerant MUST conform to Trane specification.

• Confirm refrigerant supplied is Solstice ZD R-

1233zd Refrigerant Grade.

• Confirm every container in shipment has the marking "Solstice ZD” clearly displayed on the vessel.

• Verify Certificate of Analysis with each tank in shipment.

Record Keeping Forms

An important aspect of the chiller maintenance program is the regular completion of records. Refer to

“Appendix A: Forms and Check Sheets,” p. 118

for copies of the recommended forms. When filled out accurately by the machine operator, the completed

105

logs can be reviewed to identify any developing trends in the chiller’s operating conditions. For example, if the machine operator notices a gradual increase in condensing pressure during a month’s time, she can systematically check and then correct the possible cause of this condition.

Normal Operation

Table 25. Normal operation

Operating Characteristic Normal Reading

Approximate Evaporator Pressure

Approximate Condenser Pressure (a)

8 to 13.2 psia (55.2 to 91.0 kPaA) / -6.7 to -1.5 psig (-46.2 to -10.3 kPaG)

24.2 to 37.7 psia (166.9 to 259.9 kPaA) / 9.5 to 23 psig (65.5 to 158.6 kPaG) (standard condenser)

Oil Sump Temperature Unit not running 110°F to 135°F (43.3°C to 57.2°C)

Oil Sump Temperature Unit running 110°F to 160°F (43.3°C to 71.1°C)

Oil Sump Differential Oil Pressure (b) 20 to 24 psid (137.9 to 165.5 kPaD)

(a)

(b)

Condenser pressure is dependent on condenser water temperature, and should equal the saturation pressure of R-1233zd at a temperature above that of leaving condenser water at full load.

Oil tank pressure: -7 to -4 psig (-48.3 to -27.6 kPaG). Discharge oil pressure: 13 to 20 psig (89.6 to 137.9 kPaG).

Table 26.

Recommended maintenance

Daily

Check the chiller’s evaporator and condenser pressures, oil tank pressure, differential oil pressure, and discharge oil pressure.

Compare the readings with the values provided in the preceding table.

Check the oil level in the chiller oil sump using the two sight glasses provided in the oil sump head.

When the unit is operating, the oil level should be visible in the lower sight glass.

Complete logs on a daily basis.

Every 3 months

Clean all water strainers in the water piping system.

Every 6 months

106

Annually (a)

,

(b)

Lubricate the vane control linkage bearings, ball joints, and pivot points.

Lubricate vane operator tang Orings.

Operate the tang operators manually and check for any abnormalities.

Drain contents of the rupture disk and purge discharge vent-line drip-leg into an evacuated waste container. Do this more often if the purge is operated excessively.

Apply oil to any exposed metal parts to prevent rust.

Shut down the chiller once each year to check the items listed on the

“Appendix D: CVHH

CenTraVac ™ Chiller Annual Inspection List,” p.

123

(refer to

“Appendix A: Forms and Check

Sheets,” p. 118

).

Perform the annual maintenance procedures referred to in

“Maintenance,” p. 110

.

CVHH-SVX001G-EN

Table 26. Recommended maintenance (continued)

Daily

(a)

(b)

Every 3 months Every 6 months Annually (a)

,

(b)

Use an ice water bath to verify the accuracy of the evaporator refrigerant temperature sensor

(4BT11). If the sensor is exposed to temperature extremes outside its normal operating range (0°F to 90°F [-17.8°C to 32.2°C]), check its accuracy at six-month intervals.

Inspect the condenser tubes for fouling; clean if necessary.

Inspect and clean the ifm efector ® flow detection sensors. Use Scotch-Brite ® or other non-abrasive material to clean scale; do NOT use steel wool, which could cause the probe to rust.

Submit a sample of the compressor oil to a Tranequalified laboratory for comprehensive analysis.

Measure the compressor motor winding resistance to ground; a qualified service technician should conduct this check to ensure that the findings are properly interpreted. Contact a qualified service organization to leak-test the chiller; this procedure is especially important if the system requires frequent purging.

Every three years, use a non-destructive tube test to inspect the condenser and evaporator tubes. It may be desirable to perform tube tests on these components at more frequent intervals depending upon chiller application. This is especially true of critical process equipment.

Contact a qualified service organization to determine when to conduct a complete examination of the unit to discern the condition of the compressor and internal components. Check the following: chronic air leaks (which can cause acidic conditions in the compressor oil and result in premature bearing wear) and evaporator or condenser water tube leaks (water mixed with the compressor oil can result in bearing pitting, corrosion, or excessive wear).

Table 27.

Recommended maintenance of optional features

Feature

Waterbox Coatings

Waterbox Anodes

Every 3 months

Inspect waterbox coatings within the first 1–3 months to determine a required maintenance schedule for your job site. Refer to

“Waterbox and

Tubesheet Protective Coatings,” p. 109

for more information.

Inspect waterbox anodes within the first

1–3 months to determine a required maintenance schedule for your job site.

Refer to

“Sacrificial Anodes,” p. 109

for more information.

Every 6 months

Gantries

Hinges

Annually

Lubricate the gantries annually. Use ConocoPhillips

MegaPlex ® XD3 (gray in color), LPS ® MultiPlex Multi-

Purpose (blue in color), or equivalent.

Lubricate the hinges annually. Use ConocoPhillips

MegaPlex ® XD3 (gray in color), LPS ® MultiPlex Multi-

Purpose (blue in color), or equivalent.

Recommended Compressor Oil

Change

After the first six months of accumulated operation or after 1000 hours operation—whichever comes first—it is recommended to change the oil filter. It is recommended to subscribe to the Trane annual oil analysis program rather than automatically change the oil as part of scheduled maintenance. Change the oil only if indicated by the oil analysis. Using an oil analysis program will reduce the chiller’s overall lifetime waste oil generation and minimize refrigerant emissions. The analysis determines system moisture content, acid level, and wear metal content of the oil, and can be used as a diagnostic tool. Due to the new refrigerant and oil combination, the oil analysis should be performed by the Trane Chemical Laboratory.

In conjunction with other diagnostics performed by a qualified service technician, oil analyses can provide valuable information on the performance of the chiller to help minimize operating and maintenance costs and maximize its operating life. An access valve is installed in the oil supply line, before the oil filter, for obtaining oil samples.

oil change is 21 gallons (79.5 L).

Purge System

Leak Checking Based on Purge Pump Out

Time

The following figure has been developed to aid in determining when to do a leak check of a chiller based on the purge pump-out time and unit size. This figure

CVHH-SVX001G-EN 107

depicts normal purge pump-out times, small leaks, and large leaks based on chiller tonnage.

If the purge pump-out time is in the small leak region, then a leak check should be performed and all leaks repaired at the earliest convenience. If the purge pumpout time is in the large leak region, a thorough leak check of the unit should be performed immediately to find and fix the leaks.

Figure 62.

Purge operation under typical and leak conditions

140

120

Large Leak

Small Leak

Typical Operation

100

80

60

40

20

0

400 600 800 1000 1200 1400 1600 1800 2000

Chiller Tons per Circuit

Leak Testing

eq uiip application only.

ap y d

Service Agency.

X39003892001A

108 CVHH-SVX001G-EN

Recommended System

Maintenance

4. Scale deposits are best removed by chemical means. Be sure to consult any qualified chemical house in the area (one familiar with the local water supply’s chemical mineral content) for a recommended cleaning solution suitable for the job.

composed solely of copper, cast iron, and steel.

an y,, iiss rre eq uiip

Condenser

Condenser tube fouling is indicated when the approach temperature (the difference between the condensing refrigerant temperature and the leaving condenser water temperature) is higher than predicted.

If the annual condenser tube inspection indicates that the tubes are fouled, two cleaning methods— mechanical and chemical—can be used to rid the tubes of contaminants. Use the mechanical cleaning method to remove sludge and loose material from smooth-bore tubes.

To clean other types of tubes including internallyenhanced types, consult a qualified service organization for recommendations.

Figure 63.

Typical chemical cleaning setup

Pipe

Connections

Shutoff

Valves

Circulator

Pump

Cleaning

Solution

1. Follow all instructions in

“Waterbox Removal and

Installation,” p. 113

to remove waterbox covers.

2. Work a round nylon or brass bristled brush

(attached to a rod) in and out of each of the condenser water tubes to loosen the sludge.

3. Thoroughly flush the condenser water tubes with clean water.

CVHH-SVX001G-EN da ma an d ttu o cclle an err ssiid e o circulation system, the quantity of the solution, the duration of the cleaning period, and any required safety precautions should be approved by the company furnishing the materials or performing the cleaning. Remember, however, that whenever the chemical tube cleaning method is used, it must be followed up with mechanical tube cleaning, flushing, and inspection.

Evaporator

Since the evaporator is typically part of a closed circuit, it may not accumulate appreciable amounts of scale or sludge. Normally, cleaning every three years is sufficient. However, periodic inspection and cleaning is recommended on open evaporator systems, such as air washers.

Waterbox and Tubesheet Protective

Coatings

Trane recommends that coated waterboxes/tubesheets

—regardless of the type of protective coating included

—be taken out of service within the first one to three months of operation for inspection. Any voids or defects identified upon inspection must be repaired. If the water quality is known to be highly supportive of corrosion (i.e., sea water, etc.), inspect the coating system at one month; if the water quality is known to be relatively benign (i.e., normal treated and clean condenser water), inspect the coating system within three months. Only when initial inspections show no problems are present should subsequent maintenance intervals be increased.

Sacrificial Anodes

The replacement schedule for the optional zinc or magnesium anodes can vary greatly with the

109

aggressiveness of the water that is in the system. Some sites could require anode replacement every two to three months while other sites may require anode replacement every two to three years. Trane recommends inspection of anodes for wear sometime within the first several months of the anodes being placed into service. If the observed loss of anode material is small, then the interval between subsequent inspections can be lengthened. Replace the anode and/ or shorten the inspection interval if the anode has lost

50 percent or more of its original mass. If anode depletion occurs very quickly, consult a water treatment specialist to determine if the anode material selected is correct for the application.

m cco ntta eq uiip yp e.. D ad diittiiv erra ntt u n--a pp n d ea

Diisscco nn eccttss b effo na ve eq uiip a ssm allll a eq uiiv ettw ee

As needed after draining the waterbox, use a 2-1/2 in.

(63.5 mm) wrench to remove/install Trane-supplied waterbox anodes.

RuptureGuard Maintenance

It is recommended that the RuptureGuard ™ be visually inspected and the relief valve pressure tested annually.

The test can be performed with the valve in place and the refrigerant in the chiller.

The vent-line drip-leg must be periodically checked for accumulation of water or refrigerant. Drain any accumulation that may be present into an evacuated, properly labeled vessel and dispose of in accordance with local, state, and federal codes.

EarthWise Purge

Maintenance

To ensure efficient and reliable purge operation, perform all inspections and procedures at the prescribed intervals. Keep records of inspection results to establish proper service intervals. Document changes that occur in purge activity that could provide information about chiller performance.

110

X39003892001A application only.

• Before servicing, disconnect all power sources and allow at least 30 minutes for capacitors to discharge.

• All electrical enclosures—unit or remote

—are IP2X.

CVHH-SVX001G-EN

Figure 64.

Anchor for use when performing purge maintenance

•• W

•• T

•• T

•• A

•• N an d tth

CVHH-SVX001G-EN an ya niicciia nss g iiss n ecce allll P on

Weekly Maintenance

Perform the following maintenance procedure on a weekly basis:

1. With the purge unit operating, check the purge tank condensing activity by observing the liquid refrigerant flow in the moisture-indicating sight glass located in the liquid drain line immediately after the filter drier canister. A lack of visible refrigerant flow in the sight glass indicates one of the following: a. A pump-out cycle is necessary.

b. A problem exists with the purge heat transfer circuit (such as the condensing unit, expansion device, or purge evaporator coil).

c. A problem exists in the purge control subsystem.

d. Refrigerant vapor from the chiller condenser is blocked or restricted.

2. Check the moisture-indicator sight glass. Replace the filter-drier core if moisture is indicated.

drier could be an indication of significant chiller air or tube leaks.

Semi-Annual Maintenance

Perform the following maintenance procedure on a semi-annual basis:

1. Inspect the air-cooled condenser coil and clean as needed. Clean the coil from the fan side using compressed air or coil cleaner. A dirty coil will reduce purge efficiency and capacity.

2. Inspect the purge tank and carbon tank insulation for any damage or degradation. Make any needed repairs to the insulation.

Annual Maintenance

Perform the following maintenance procedure on an annual basis:

1. Semi-annual maintenance procedures described in

“Semi-Annual Maintenance,” p. 111 .

2. Open the purge control panel and check all internal components for such problems as corrosion, terminal tightness, or signs of overheating.

111

3. Change the filter-drier assembly.

Inspecting the Moisture Indicator

Monitor the quality of the liquid refrigerant in the chiller by periodically inspecting the moisture indicator. The indicator will show “wet” whenever the chiller moisture exceeds the levels shown in the following table. Notice that the indicator becomes more sensitive as the temperature decreases. (The moisture indicator normally operates at equipment room ambient temperatures.)

A “wet” indication for more than 72 hours typically indicates that the filter-drier is saturated and should be replaced. In some cases in which a substantial amount of moisture has accumulated, such as when the chiller has been serviced, several filter-drier assembly changes may be required before a satisfactory moisture level is achieved. A reoccurring or persistent

“wet” indication is a sign of possible chiller air or water infiltration.

Inspect the moisture indicator only under the following conditions:

• The chiller is operating.

• The purge unit is operating and has been allowed sufficient time to properly remove system moisture

(allow a minimum of 72 hours after replacing filterdrier).

Table 28.

R-1233zd refrigerant moisture content as determined by moisture indicator

Refrigerant moisture level

Dry

75°F

(23.9°C)

Below 20

100°F

(37.8°C)

Below 30

125°F

(51.7°C)

Below 35

Caution 20–50 30–80 35–100

Wet Above 50 Above 80 Above 100

Note: Refrigerant moisture content given in parts per million (ppm).

Maintaining the Moisture-Indicating Sight

Glass

In normal operating conditions, the moisture-indicating sight glass should not require maintenance beyond keeping the sight glass clean. However, the sight glass should be replaced after any major repair to the unit has taken place, or if it is on a unit in which severe moisture contamination is known to have occurred.

Be aware that it is normal for the sight glass to indicate the presence of moisture for a period of least 72 hours after it is installed and after it has been exposed to atmosphere. Allow a minimum of 72 hours after sight glass installation or filter-drier service before using the sight glass to determine the system moisture content.

Removing Air After Servicing the Chiller

Air that leaks into a chiller during servicing needs to be removed so that the chiller can operate normally. The purge pump-out system, which performs this function, may operate for a long time to remove the air before cycling off for the first time. This is due to the large amount of non-condensables and the relatively small amount of refrigerant being drawn into the purge tank.

restrictor of the EarthWise ™ purge system.

Doing so could reduce the efficiency of the purge system. The purge system has a faster air exhaust rate than previous purge systems, which makes bypassing or removing the restrictor unnecessary.

The Daily Pumpout Limit determines how long the purge pump-out compressor can operate continuously without generating a Purge Daily Pumpout Exceeded diagnostic, which will shut off the purge system. You can disable the Daily Pumpout Limit to allow the purge to pump out for an extended period of time.

After the level of non-condensables present in the chiller falls to a point in which an increasing amount of refrigerant enters the purge tank, the pump-out compressor begins to cycle on and off. As the refrigerant in the system becomes less contaminated with non-condensables, purge pump-out is activated less frequently.

present in the chiller, the air removal rate can be enhanced by operating the chiller at part-load conditions.

112 CVHH-SVX001G-EN

Waterbox Removal and Installation

the installation and servicing of this equipment.

safest method or methods of rigging and lifting the waterboxes.

1. Determine the type and size of chiller being serviced. Refer to Trane ® nameplate located on chiller control panel.

Discussion

This section will discuss recommended lifting. Proper lifting technique will vary based on mechanical room layout.

• It is the responsibility of the person(s) performing the work to be properly trained in the safe practice of rigging, lifting, securing, and fastening of the waterbox.

• It is the responsibility of the person(s) providing and using the rigging and lifting devices to inspect these devices to ensure they are free from defect and are rated to meet or exceed the published weight of the waterbox.

• Always use rigging and lifting devices in accordance with the applicable instructions for such device.

Procedure

information only for Trane CenTraVac ™ chillers built in La Crosse. For Trane

CenTraVac ™ chillers built outside the

United States, refer to literature provided by the applicable manufacturing location.

2. The rated lifting capacity of the lifting shackle must meet or exceed the published weight of the waterbox. Verify the waterbox weight from the latest published literature.

3. Ensure that the lift connection device has the correct size for the waterbox lifting hole.

4. Properly connect the shackle to the waterbox. Refer to the following figure

5. Disconnect water pipes, if connected.

6. Remove hex head bolts.

7. Lift the waterbox away from the shell.

de atth ov errh ess ((cch aiin x m usstt b e cca pa orr sslliin gss)) m orr w atte otte

“Torque Requirements and Waterbox

Weights,” p. 114

for waterbox weights.

an d b en de

8. Store waterbox in a safe and secure location and position.

lifting device.

n d ea grra du niiffiicca nttlly oiid ed he

Lo ad an e o

Review mechanical room limitations and determine the

CVHH-SVX001G-EN 113

Figure 65.

Waterbox lifting—condenser and evaporator lifting points

Lifting

Location

Lifting

Location

Reassembly

Once service is complete, the waterbox should be reinstalled on the shell following all previous procedures in reverse. Use new O-rings or gaskets on all joints after thoroughly cleaning each joint.

“Torque Requirements and Waterbox

Weights,” p. 114

.

Lifting

Location

Lifting

Location

Torque Requirements and Waterbox Weights

Table 29.

CenTraVac chiller screw torques

Screw Size Gasket type O-ring in.

3/8 mm

9.525

1/2 12.7

5/8 15.875

ft·lb

25

70

150

N·m

33.9

94.9

203.4

3/4 19.05

250 339.0

ft·lb

12–18

Flat

N·m

16.3–24.4

33–50

70–90

105–155

44.7–67.8

94.9–122.0

142.4–

210.2

114 CVHH-SVX001G-EN

Table 30. Waterbox weights (IP units)

Shell

Size

Description

Evaporator, 150 psig

Non-Marine

(lb)

Plate

Weight

Lifting

Hole

(in.)

— —

Evaporator, 300 psig 814 0.469

100

Condenser, 150 psig — —

Condenser, 300 psig — —

Evaporator, 150 psig — —

Evaporator, 300 psig 950

130

0.469

Condenser, 150 psig — —

Condenser, 300 psig — —

160

Evaporator, 150 psig

Evaporator, 300 psig

1200

0.469

Evaporator, 150 psig

Evaporator, 300 psig

2211

0.469

200

Condenser, 150 psig — —

Condenser, 300 psig — —

Evaporator, 150 psig — —

Evaporator, 300 psig 3218

220

0.469

Condenser, 150 psig — —

10H

13H

20H

22H

Condenser, 300 psig

Heat Recovery Condenser,

150 psig

Heat Recovery Condenser,

150 psig

Heat Recovery Condenser,

150 psig

Heat Recovery Condenser,

150 psig

2022

2439

2750

3853

0.858

0.858

0.858

0.858

652

700

802

763

1132

Non-Marine

Dome

Weight

(lb)

Lifting

Hole

(in.)

693 0.469

Marine Plate

(lb)

Cover

Weight

Lifting

Hole

(in.)

— —

589

851

863

448

642

766

0.469

0.469

0.469

0.469

0.469

0.469

705

906

814

0.469

0.469

0.469

Marine Dome

(lb)

Cover

Weight

Lifting

Hole

(in.)

569 0.469

Marine

Waterbox

Weight

(lb)

Lifting

Hole

(in.)

1292 0.858

409

562

683

324

436

645

0.469

0.469

0.469

0.469

0.469

0.469

1365

953

1195

1423

1527

1166

1513

1813

1937

1.38

0.858

0.858

0.858

1.38

0.858

0.858

0.858

1.38

0.469

0.469

0.469

0.469

0.469

0.469

1282

1763

1724

1702

2476

0.469

0.469

0.469

0.469

0.469

0.469

543

708

0.469

0.469

1918

2849

1544

2138

2677

4137

1598

1901

1.38

1.38

0.858

0.858

1.38

1.38

0.858

0.858

CVHH-SVX001G-EN 115

Table 31. Waterbox weights (SI units)

Shell

Size

Description

Evaporator, 1034.2 kPaG

Non-Marine

Plate

Weight

(kg)

Lifting

Hole

(mm)

— —

Evaporator, 2068.4 kPaG 369 11.9

100

Condenser, 1034.2 kPaG — —

Condenser, 2068.4 kPaG — —

Evaporator, 1034.2 kPaG — —

Evaporator, 2068.4 kPaG 431

130

11.9

Condenser, 1034.2 kPaG — —

Condenser, 2068.4 kPaG — —

Evaporator, 1034.2 kPaG

160

Evaporator, 2068.4 kPaG

544

11.9

200

220

10H

13H

20H

22H

Evaporator, 1034.2 kPaG

Evaporator, 2068.4 kPaG

Condenser, 1034.2 kPaG

Condenser, 2068.4 kPaG

Evaporator, 1034.2 kPaG

Evaporator, 2068.4 kPaG

Condenser, 1034.2 kPaG

Condenser, 2068.4 kPaG

Heat Recovery Condenser,

1034.2 kPaG

Heat Recovery Condenser,

1034.2 kPaG

Heat Recovery Condenser,

1034.2 kPaG

Heat Recovery Condenser,

1034.2 kPaG

1003

1459

917

1106

1247

1747

11.9

11.9

21.8

21.8

21.8

21.8

Non-Marine

Dome

Weight

(kg)

Lifting

Hole

(mm)

314 11.9

Marine Plate

Cover

Weight

(kg)

Lifting

Hole

(mm)

— —

267

386

391

203

291

347

364

346

513

295

317

11.9

11.9

11.9

11.9

11.9

11.9

11.9

11.9

11.9

11.9

11.9

11.9

320

411

369

581

799

782

772

1123

11.9

11.9

11.9

11.9

11.9

11.9

11.9

11.9

11.9

Marine Dome

Cover

Weight

(kg)

Lifting

Hole

(mm)

258 11.9

Marine

Waterbox

Weight

(kg)

Lifting

Hole

(mm)

586 21.8

185

255

310

147

198

292

246

321

11.9

11.9

11.9

11.9

11.9

11.9

11.9

11.9

693

529

686

822

878

619

432

542

645

870

1292

700

970

1214

1876

724

862

35.1

21.8

21.8

21.8

35.1

21.8

21.8

21.8

35.1

35.1

35.1

21.8

21.8

35.1

35.1

21.8

21.8

Screw-Tightening Sequence for

Waterboxes

Evaporator Waterbox Covers

Ensure that the waterbox head rests tightly against the tube sheet, and then snugly tighten the screws in sequential order as shown in the following figure. If excessive tube sheet crown prevents the head from contacting the tube sheet, tighten the screws located where the greatest gaps occur. Be sure to use an equal number of screw turns from side to side. Then, apply final torque to each screw in sequential order.

Figure 66.

Evaporator waterbox cover screw tightening sequence

7

21 13 3 1 11 19

5

17

15

25

9

24

16

6

4 14 22

8

18

23

10

26

20 12 2

Condenser Waterbox Covers

Condenser waterbox covers use a similar procedure to that which is used for the evaporator waterbox covers.

Use a crossing pattern as shown in the following figure.

116 CVHH-SVX001G-EN

Figure 67.

Condenser waterbox cover screw tightening sequence

1 5

9

13

17

21

16

12

20

24

8 3

4

23

19

15

7

11

22

18

14

10

6 2

Heat Recovery Condenser Waterbox

Covers

For heat recovery condenser waterbox covers, torque the screws along the center divider of the waterbox first (1A, 2A, 3A, etc), and then torque the scfrews around the outside of the waterbox (1B, 2B, 3B, etc).

Figure 68. Heat recovery condenser waterbox cover screw tightening sequence

3B

7B 11B

15B

19B

23B

22B

18B

14B

10B

6B

2B

6A

4A

2A

1A

3A

5A

7A

1B

5B

9B

13B

17B

21B

24B

20B

16B

12B 8B 4B

CVHH-SVX001G-EN 117

Appendix A: Forms and Check Sheets

The following forms and check sheets are included for use with Trane start-up of CVHH CenTraVac ™ chillers.

Forms and check sheets are used, as appropriate, for installation completion verification before Trane startup is scheduled, and for reference during the Trane start-up.

Where the form or check sheet also exists outside of this publication as standalone literature, the literature order number is also listed.

“Appendix B: CenTraVac ™ Chiller Installation

Completion and Request for Trane Service,” p. 119

(CTV-ADF001*-EN)

“Appendix C: CVHH CenTraVac ™ Chiller Start-up

Tasks to be Performed by Trane,” p. 121

“Appendix D: CVHH CenTraVac ™ Chiller Annual

Inspection List,” p. 123

“Appendix E: CVHH CenTraVac ™ Chiller Operator

Log,” p. 124

Unit Start-up/Commissioning

agent of Trane specifically authorized to perform start-up and warranty of Trane ® products. Contractor shall provide Trane

(or an agent of Trane specifically authorized to perform start-up) with notice of the scheduled start-up at least two weeks prior to the scheduled start-up.

118 CVHH-SVX001G-EN

Appendix B: CenTraVac

Chiller Installation

Completion and Request for Trane Service

submitted to the Trane Service Agency that will be responsible for the start-up of the chiller. Start-up will NOT proceed unless applicable items listed in this form have been satisfactorily completed.

TO:

TRANE SERVICE OFFICE:

S.O. NUMBER:

SERIAL NUMBERS:

JOB/PROJECT NAME:

ADDRESS:

The following items are being installed and will be completed by: agent of Trane specifically authorized to perform start-up and warranty of Trane ® products. Contractor shall provide Trane

(or an agent of Trane specifically authorized to perform start-up) with notice of the scheduled start-up at least two weeks prior to the scheduled start-up. E qu an e iiss n arrrra ntte otte ™ chillers, including optional components, can result in start-up delay and required rework. Follow all provided instructions and in use particular care with optional devices:

• Follow installation procedures for

RuptureGuard ™ ; refer to CTV-SVX06*-EN for CDHF, CDHG, CVHE, CVHF, CVHG, CVHL,

CVHM, and CVHS models, refer to CDHH-

SVX001*-EN for CDHH models, and refer to

CVHH-SVX001*-EN for CVHH CenTraVac ™ chiller models.

• Do NOT over-insert or over-torque the probe of the ifm efector ™ flow detection controller and sensor; refer to PART-SVN223*-EN or the CenTraVac ™ chiller Installation,

Operation, and Maintenance manual.

• Do NOT block serviceable parts when installing isolation springs.

Expenses that result in improper installation of

CenTraVac ™ chillers, including optional components, will NOT be paid by Trane.

Check box if the task is complete or if the answer is

“yes”.

en Trra Va ™ C

CVHH-SVX001G-EN

In place and piped.

otte ™ chiller or adjacent piping prior to the chiller commissioning by Trane service personnel.

The contractor is responsible for any foreign material left in the unit.

Chilled water piping connected to:

CenTraVac ™ chiller

Air handling units

Pumps

Optional ifm efector ® flow detection controller and sensor properly installed

Condenser and heat recovery condenser (as applicable) piping connected to:

CenTraVac ™ chiller

Pumps

Cooling tower

Heating loop (as applicable)

Additional piping:

Make-up water connected to cooling tower

Water supply connected to filling system

Systems filled

Pumps run, air bled from system

Strainers cleaned

Rupture disk or RuptureGuard ™ ventilation piping properly installed

Optional RuptureGuard ™ properly installed

Leaving chilled water

Leaving condenser water

Optional heat recovery or auxiliary condenser water an d a

Installed on both sides of evaporator

Installed on both sides of condenser and heat recovery condenser (as applicable)

Compressor motor starter has been furnished by Trane, or has been configured and installed in compliance with the appropriate Trane

Engineering Specification for Starter by Others

(available from your local Trane Sales Office)

Full power available

119

120

Va ™ C hiilllle

Interconnecting wiring, starter to panel (as required)

External interlocks (flow switch, pumps auxiliary, etc.)

Chiller motor connection (remote starters) compressor motor connections until requested to do so by the Trane service representative!

Chilled water pump (connected and tested)

Condenser water pump (connected and tested)

Optional ifm efector ® flow detection controller and sensor cable properly installed and secured for non-stress at probe connector

Cooling tower fan rotation checked

Heat recovery condenser water pump (as applicable)

115 Vac power available for service tools

All controls installed and connected

All magnetic starters installed and connected

Dry nitrogen available for pressure testing (for disassembled units)

Material and equipment available for leak testing, if necessary erra ntt

For CDHH and CVHH chillers: Verify supplied refrigerant is “Solstice ZD” Refrigeration Grade by checking certificates provided with tanks.

Refrigerant on job site and in close proximity to chiller.

Total amount in cylinders/drums:

___________ (specify lb or kg) and fill in specifics below:

Number of cylinders/drums _____ of size

_____ (specify lb or kg)

Number of cylinders/drums _____ of size

_____ (specify lb or kg) installer’s responsibility to transport empty refrigerant containers to an easily accessible point of loading to facilitate container return or recycling.

Systems can be operated under load conditions

Electrical, control man, and contractor’s representative are available to evacuate, charge, and test the CenTraVac ™ chiller under serviceman’s supervision uiip en

Does the equipment room have a refrigerant monitor/sensor capable of monitoring and alarming within the allowable exposure level of the refrigerant?

Does the installation have properly placed and operating audible and visual refrigerant alarms?

Does the equipment room have proper mechanical ventilation?

If it is required by local code, is a self-contained breathing apparatus available?

Has the owner been fully instructed on the proper use and handling of refrigerant?

Does the owner have a copy of the MSDS for refrigerant?

the start-up and commissioning, due to any incompleteness of the installation, will be invoiced at prevailing rates.

This is to certify that the Trane equipment has been properly and completely installed, and that the applicable items listed above have been satisfactorily completed.

Checklist Completed by

(Print Name):

SIGNATURE:

DATE:

In accordance with your quotation and our purchase order number ______________, we therefore require the presence of Trane service on this site, for the purpose of start-up and commissioning, by ______________

(date).

required to allow for scheduling of the chiller start-up.

ADDITIONAL COMMENTS/INSTRUCTIONS

CVHH-SVX001G-EN

Appendix C: CVHH CenTraVac

Chiller Start-up Tasks to be Performed by Trane

de atth

•• F

•• P

•• R an d u n S ub an d M niin gss,, cca uttiio nss,, a

Inspect chiller for damage (shipping or rigging).

Verify and record unit nitrogen holding charge pressure.

Inspect water piping for proper installation.

Inspect strainers, flow sensing devices, isolation valves, pressure gauges, thermometer wells, flow balancing valves, vent cocks, and drains.

Inspect cooling tower piping.

Verify proper clearances.

Power wiring meets size requirement.

Verify proper voltage and amperage rating.

Verify proper foundation installation.

Verify unit isolator pads/springs have been installed.

Verify low voltage circuits are isolated from high voltage circuits.

Check equipment room for ventilation, refrigerant monitor, rupture disk piping, and

Personal Protective Equipment (PPE).

established requirements for unit installation

MUST be corrected prior to start-up. Any nonconforming condition which is not corrected prior to start-up must be noted in the Non-

Compliance Form (PROD-ADF001*-EN) by the start-up technician; this information must also be signed by responsible site personnel before start-up and the completed Non-Compliance

Form will become part of the start-up record, submitted with a Start-up Check Sheet and a

Chiller Service Report .

Op erra

Verify nitrogen holding charge.

Calibrate the high pressure cutout control

(HPC).

Meg compressor motor.

Check condenser installation.

Check evaporator installation.

an om

Check electrical and controls.

Inspect motor starter and control panel.

Confirm all wiring connections are tight, free of abrasion and have no sharp bends in panel and on compressors.

Inspect contactors and relays.

Verify unit wiring (low and high voltage) is correctly isolated, phased, and properly grounded.

Connect external 120 Vac power to power up the control panel.

Run the oil pump to verify pump can provide

(20 to 24 psid)137.9 to 165.5 kPaD net

121 CVHH-SVX001G-EN

122

Va ™ C hiilllle

pressure.

Verify and record control parameters.

Verify all control interlocks are installed and properly functioning.

Dry run starter (non-Adaptive Frequency ™

Drive [AFD]).

Measure condenser pressures and flow.

Adjust condenser flow sensing device.

Measure evaporator pressures and flow.

Adjust evaporator flow sensing device.

Inspect motor starter panel and perform starter panel checkout procedures.

Confirm proper phase check incoming power.

Inspect control panel.

Apply separate source 120 Vac power to control to perform control panel checkout procedure.

Review and record unit configuration parameters.

Verify the operation of the oil tank vent valve.

Verify that the oil cooling line valve actuates.

Verify vane operator is working properly and moves without binding.

Dry run test starter (non-AFD).

Remove separate source power and reconnect wiring.

ep attiio

Relieve nitrogen holding charge.

Confirm proper oil pump operation.

Confirm oil pump pressure—regulating valve setting.

Evacuate and charge the system.

Apply power to the starter panel.

Verify current to the oil sump heater.

Set Purge mode to “On.”

Bump-start the compressor and verify compressor motor rotation.

Start chiller.

Verify no unusual noises or vibrations and observe operating conditions.

If necessary, adjust oil pressure regulator between 20 to 24 psid (137.9 to 165.5 kPaD) net.

Measure and verify refrigerant pump pressure.

When chiller is stable, take system log three times at 15-minute intervals.

Set Purge mode to “Adaptive.”

Reset the “Starter Energy Consumption” resettable.

Record a Chiller Service Report .

Review “AdaptiView Display Customer Training

Checklist.”

Equipment Description

Stopping/Starting Chiller Operation

Alarms

Reports

Data Graphs

Equipment Settings

Display Settings

Security Settings

Basic Troubleshooting

CVHH-SVX001G-EN

Appendix D: CVHH CenTraVac

Chiller Annual

Inspection List

Follow the annual maintenance instructions provided in the text of this manual, including but not limited to:

Motor continuity.

Motor meg test.

Check motor terminals.

Inspect motor terminal board.

Check inlet guide vanes (IGV) for abnormalities.

nccy ™ D ve

Inspect starter contacts.

Check all connections per manufacturer specifications.

Follow all manufacturer recommendations for starter or Adaptive Frequency ™ Drive (AFD) maintenance.

Inspect/clean/service the AFD cooling system

(water- or air-cooled AFD).

Record all applicable starter or starter component settings.

Annual oil analysis (follow recommendations).

Clean and lubricate oil system as required.

Electrical inspection.

Pump motor continuity check.

Run oil pump and check differential oil pressure.

Verify control parameters.

Test appropriate sensors for accuracy.

Ensure sensors are properly seated in wells with thermopaste installed.

Check evaporator leaving water temperature low temperature cutout setpoint.

Condenser high pressure switch check-out.

Check adjustment and operation of the inlet guide vane actuator.

Check purge times and unit performance logs. If warranted, pressure leak test.

Review oil analysis. If required, submit refrigerant sample for analysis.

Inspect unit for any signs of refrigerant or oil leakage.

Check unit for any loose screws on flange, volutes, or casing.

Review the purge the purge sections of this manual and follow maintenance and/or inspection items identified.

Review purge pump-out data.

Review overall operation of purge and service as necessary.

Inspect for fouling and scaling in tubes.

Check operation of condenser water flow sensing device.

Factory recommendation to eddy current test tubes every three years.

Inspect for fouling and scaling in tubes.

Check operation of evaporator water flow sensing device.

Factory recommendation to eddy current test tubes every three years.

Inlet guide vane linkage.

Clean and touch-up painted surfaces as needed.

Repair deteriorated, torn, or missing insulation.

If applicable, lubricate factory-installed gantries.

After the first month of operation, inspect

Heresite ® or Belzona ® coated waterboxes; thereafter, inspect as needed.

Inspect anodes.

Inspect and lubricate hinged waterboxes.

With water flow sensing option, bleed tubing from waterboxes to transformers.

CVHH-SVX001G-EN 123

Appendix E: CVHH CenTraVac

Chiller Operator Log

Water-Cooled CVHH CenTraVac ™ Chillers with UC800 Controller

Tracer ® AdaptiView ™ Reports—Log Sheet Log 1

Evaporator

Entering

Leaving

Saturated

Refrig. Press

Approach

Flow Sw Status

Condenser

Entering

Leaving

Saturated

Refrig. Press

Approach

Flow Sw Status

Compressor

Starts

Running Time

Oil Tank Press

Oil Discharge Press

Oil Diff Press

Oil Tank Temp

IGV Position %

Outboard Bearing Pad Temperature #1

Outboard Bearing Pad Temperature #2

Outboard Bearing Pad Temperature #3

Motor

% RLA L1, L2, L3

Amps L1, L2, L3

Volts AB, BC, CA

Power KW

Load PF

Winding #1 Temp

Winding #2 Temp

Winding #3 Temp

With AFD only

AFD Freq

AFD Speed

AFD Transistor Temp

Purge

Time Until Next Purge Run

Daily Pumpout—24 hrs

Avg. Daily Pumpout—7 days

Daily Pumpout Limit/Alarm

Chiller On—7 days

Pumpout Chiller On—7 days

Pumpout Chiller Off—7 days

Pumpout—Life

Log 2 Log 3

124 CVHH-SVX001G-EN

Water-Cooled CVHH CenTraVac ™ Chillers with UC800 Controller

Tracer ® AdaptiView ™ Reports—Log Sheet Log 1

Purge Rfgt Cprsr Suction Temp.

Purge Liquid Temp.

Carbon Tank Temp. (if present)

Date:

Technician:

Owner:

Log 2

Va ™ C hiilllle

Log 3

CVHH-SVX001G-EN 125

126 CVHH-SVX001G-EN

CVHH-SVX001G-EN 127

Ingersoll Rand (NYSE: IR) advances the quality of life by creating comfortable, sustainable and efficient environments. Our people and our family of brands — including Club Car ® , Ingersoll Rand ® , Thermo King ® and

Trane ® — work together to enhance the quality and comfort of air in homes and buildings; transport and protect food and perishables; and increase industrial productivity and efficiency. We are a global business committed to a world of sustainable progress and enduring results.

ingersollrand.com

Ingersoll Rand has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice.

We are committed to using environmentally conscious print practices.

CVHH-SVX001G-EN 01 Feb 2018

Supersedes CVHH-SVX001F-EN (March 2017) ©2018 Ingersoll Rand

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